' Balmar Max Charge Mc 612'
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Max Charge MC612 Regulator Installation and Operators ManualI MaxCharge MC612 is the most available Designed to continually monitor battery voltage and charging the MC612 uses up to 12 timeand voltage increments to ensure your a full charge quickly and safelyThe MC612 lets you choose from a variety of programs to best suit your charging needs ItsUniversal Factory Program allows you to connect the MC612 toyour alternator right out of the box Six additional preset programs support most popular battery types including standard and deepcycle flooded batteries AGM gel and Optima spiral wound technologies as well as special settings forsystems supplying halogen lighting An easytouse magnetic reed switch delivers quick precise regulator your charging system require individualized adjustment the MC612 provides additional advanced optionsWhen used with optional alternator and battery temperature sensors the MC612 automatically monitors ambient alternator and battery temperatures and compensates by adjusting field output to match conditions Alarm outputs connectto audible or visual alarms to provide warnings of dangerous CAUTIONII SAFETY CONSIDERATIONS The following instructions areBefore 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 youresult in personal injury or damage to your electrical system are not experienced at installing1 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 technician2 Remove loosefitting clothing or jewelry which could become entangled in your motor or other machinery3 Wear ANSIapproved safety glasses4 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 15 Do not attempt installation if tired or fatigued II Safety Considerations 1 III Issues 26 Ensure the engine has cooled before initiating installation Warranty 27 Do not attempt installation while using alcohol or any medication that IV Regulator Installation 3 could impair your judgment or reaction time V Alarm and Sensor Installation 48 Always use the right tool for the job Improper tool use may damage VI Basic Programming 4 the regulator or your boat and could result in personal injury VII Advanced Programming 69 Take time to read the manual Equipment damage and possible IX 8 injuries may result from an incomplete understanding of the installa Suggested Wiring Options 1011 tion and operation of the MC612 regulator If you are unfamiliar with Express Installation Instructions12 marine electrical systems consult with a licensed marine electrician 19009 61st Ave NE Arlington WA 98223 PHONE 360 4356100 FAX 360 4353210 EMAIL WEB WWWBALMARNET Copyright 2001 Ballard Commercial Industries Inc Revised 3152003 1III ISSUESThe following information is essential to the proper operation of your Max Charge regulator Do not install or operate before reviewing the following1 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 harness2 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 recommended3 VOLTAGE READINGS MC612 digital circuitry is engineered to monitor battery charge state and automatically compensate for changes in battery voltage during operation As a result it is NOT unusual to see nearconstant 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 loads5 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 voltage4 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 charging5 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 26C6 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 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 responsibility 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 identification 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 transportation 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 wwwbalmarnet 2IV REGULATOR INSTALLATION1 Mount the regulator in a dry wellventilated 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 damage2 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 harness3 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 30 404 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 Undersizing5 Attach the 4conductor harness plug to the regulator see illustration 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 recommended6 Connect BLUE field and WHITE stator wires to plug or ring terminal connectors at alternator May vary by alternator type7 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 batteries Figure 3 Regulator terminal layout 3V ALARM AND SENSOR Temperature Sensor MCTSA OptionalThe Alternator Temperature Sensor enables the regulator to sense when alternator safe limits The MC612 responds by reducing the field current at the alternator and activating the alarm output To install the Alternator Temperature Sensor1 Attach the positive and negative wires to the Alternator Temperature Sensor terminals on the MC612 See Figure 4 Observe proper polarity at the terminals2 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 notintended as a method to maintain alternator temperature Optional temperature sensors are not a guaranteeof protection against damage from overheat your system as quickly as possible if the sensoralarm is Temperature Sensor MCTSB OptionalWhen equipped with an optional Battery the MC612 will automatically compensate forvariation above and below normal MC612 is equipped with dual battery sensors toenable sensing at two separate batteries To ensureproper operation be sure the battery terminals are com Figure 5 Mounting temp sensor Figure 6 Mounting temperature senpletely clean and free of corrosion prior to installation midcase on small case alternator sor on battery negative terminal postTo install the Battery Temperature Sensor1 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 Lamp2 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 040Note Battery 1 terminal is capable of temperature compensation and activating warn High temperature at battery 1 020ing alarm Battery 2 terminal activates the warning alarm only The upper voltage limit High temperature at battery 2 021for battery temp compensation is 148 volts If higher limits are desired adjust voltage lev High temperature at alternator 022els in the Compensation Limit CL mode of the advanced programming adjustments Aux 1 Advisory OutputLamp Alarm Outputs 05 amp when in alarm modeTwo 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 051max 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 theexact cause for the alarm in Long Display Specific advisory codes are shown in Figure 17 Figure 7 Dash Lamp and Aux 1 advisory output functionsSmall Engine ModeThe MC612 can be switched to provide a halfpower setting by installing a toggle switch between the positive and negative terminalsof the alternator temperature sensor circuit When activated by closing the switch the regulator reduces the alternator output by amaximum 50 This mode is ideal for smaller engines that are not capable of providing suitable horsepower to drive both the alternator and propeller at full output When in Small Engine Mode the regulator will send a signal to the Auxiliary 1 Status OutputVI BASIC PROGRANNINGThe Model MC612 provides a wide range of operational programming and diagnostic data through its 3digit numeric LED readoutAfter an initial startup period the numeric LED will cycle through the Short Display shown in Figure 8 on the following page Theshort display includes manufacturer model battery type charging cycle actual voltage and target voltage This display cycles continuously during regulator operation In addition to its Universal default factory program which can be used safely with most battery types the MC612 features programs for gel standard lead acid deepcycle lead acid AGM absorbed glass mat Optima spiral as well as halogen applications 4The MC612 is equipped with a magnetic reed switch embedded in the epoxy potting whichactivates the regulators programming The switch works in two specific actions described inthe 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 ACTIVATEHOLD 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 resetTo set the regulator for your desired battery program1 ACTIVATEHOLD the switch The display will show the Pro mode indicating that the Program mode has been activated2 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 dot3 RELEASE when the desired value is attained between second4 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 selectedIf no changes are made the program you have selectedwill be locked into permanent memory until modified TheSAV code will be displayed indicating the program hasbeen locked into memoryCharging StagesThe MC612 uses up to 12 individual stages to ensureproper charging Each stage may contain a specific volt Figure 9 Location of magnetic reedage or time value or a combination of values These switch Long display preset programstages are displayed in both Short and Long Display ming and advanced programming aremodes 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 NoFigure 11 Preset program values Voltages shown may vary by 3 from values shown Caution Some battery technologies may bedamaged by equalization voltage Contact your battery manufacturer for specific requirements regarding equalization 5Long DisplayTo access the Long Display switch with themagnetic programming tool while the Short Display is cyclingThe numeric LED return to the beginning of the cycle The longdisplay will begin with the same elements shown in Figure 8Additional information as detailed in Figure 13 will followThe display will scroll throught the long program once to the short for these codes can be found in Figure 14 Toreset advisory codes access the Advanced Programming modeas described at the beginning of Section VIII AP mode willcycle three times and return to normal mode Codes will automatically reset when AP mode is complete Figure 12 Charge stage codes as seen in Long DisplayVII ADVANCED programming AP program customization Any changes in AP will be basedon the previouslyset battery the basic battery programwill automatically clear any settings To access1 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 nal 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 batteryStart Delay PrA Mode 2 2 temperature sensing termi nal CODE 050 Open field CODE 051 Small Engine Mode activatedThe 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 operation1 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 codes2 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 3When equipped with optional Battery Temperature Sensor theMC612 will automatically adjustcharging voltage to compensatefor battery temperatureIn default mode the regulator islimited to maximum compensated voltage of 148 volts to minimize the likelihood of overvoltage Limit allows theuser to advance or compensated voltageto suit specific charging system Figure 16 Indicates Figure 15 Advanced Programming PrAneeds Compensation Limit mode 6Compensation Limit ContinuedTo adjust voltage compensation limits1 ACTIVATEHOLD switch when CL is displayed see Figure 16 Value 148 will be highlighted Display will scroll upward RELEASE when desired value is shown2 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 8User adjustment of charging voltage above or below preset levels is possible in PrA modes 4 6 and 8To adjust voltages in bulk absorption or float stages1 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 shown2 To reduce voltage ACTIVATEHOLD until voltage values begin to climb RELEASE When voltage mode is rehighlighted 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 shownAdvanced Minimum Time Adjustment Bulk Absorption Float PrA Modes 5 7 9Minimum charging time above or below preset levels is adjustable in PrA modes 5 7 and 9 Adjustmentsare in tenths of an hour To adjust minimum times in bulk absorption or float stages1 ACTIVATEHOLD switch when the desired code is displayed see Figure 18 Blcbulk A1cabsorption and F1cfloat time Standard preset program times will be highlighted Display will scroll upward RELEASE when desired value is shown2 To reduce minimum time ACTIVATEHOLD until time values begin to climb RELEASE When pro gramming mode is rehighlighted eg B1c REACTIVATE and HOLD Minimum time values will scroll in opposite direction RELEASE when desired value is reached Figure 18 Time adjustmentAmp Manager AP PrA Mode 10 Absorption time shownThe Amp Manager function enables you to reduce the alternator output by limiting alternator field Thisfeature can be used as a method to minimize alternator overheating when alternator is undersized to thebattery bank as well as minimizing difficulties with chronic belt slippage Amp Manager adjustments aremade in 2 increments To adjust Amp Manager values1 ACTIVATEHOLD when display cycles to AP See Figure 19 PrA Mode 09 AP will be fol lowed by OFF code RELEASE2 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 ManagerNote The value 185 represents approximately 75 field output 125 represents approximately mode50 field output and 65 represents approximately 25 field Mode EQ PrA Modes 11 12Allows increase in charging voltage to minimize battery sulfation Equalization is ONLY suggested forbatteries 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 aresaved into the regulators programming the equalization process will start immediately Once equalization has occurred the regulator will revert to its preset program status The user will need to reactivate equalization mode for subsequent equalizations For system safety equalization voltage is limited Figure 20 EQ voltage modeto 158 volts NOTE BOTH EQUALIZATION TIME AND VOLTAGE MUST BE SET TO INITIATE CHARGETo adjust equalization voltage PrA Mode 111 PrA display cycles to Ev followed by OFF code2 ACTIVATEHOLD OFF display cycles to numeric voltage values When the ommended voltage is reached RELEASETo adjust equalization time PrA Mode 121 PrA Display cycles to Ec followed by OFF code2 ACTIVATEHOLD OFF display cycles to numeric equalization time values When the manufac Figure 21 EQ time mode time value is reached RELEASE 7Field Threshold Control FbA FFL PrA Mode 13 14The regulator utilizes a number of factors when determining when to change between charging stagesA primary factor considered is the amount of energy the alternator is having to expel to meet batteryloads This alternator workload can be determined by monitoring the percentage of field current theregulator 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 isworking In preset programming target field voltage under 75 is considered the standard thresholdfor advancement to the next charging stage among other factorsIn applications where the alternator is oversized for the battery load it may be necessary to reduce Figure 22 Field Thresholdthe threshold below the standard 75 to ensure that the batteries continue to charge efficiently adjustment Bulk toInversely if an alternator is undersized for the battery load the threshold can be raised to reduce Absorption display is shownundue 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 toeither mode of adjustment To adjust1 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 reached2 To reverse the direction of scroll REACTIVATE and HOLD when the FbA or FFL codes are high lighted RELEASE when desired value is reachedNote The value 220 represents approximately 165 field output 110 represents approximately Figure 22 Field Threshold50 field output and 55 represents approximately 25 field output adjustment Field to Float display is shownVIII SYSTEM majority of charging difficulties can be attributed to damage corrosion or wear at wires or wiring connections Before attempting to troubleshoot potential alternator or regulator issues be sure to address the following1 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 replaced2 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 condition3 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 availableAfter 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 orregulator The following tests provide an opportunity to isolate the alternator regulator and wiring harness in order to determine which component may be malfunctioning 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 usedto help determine if power or working grounds exist An amp meter and a with a thermometer are also helpful diagnostic tools Regulator TestAfter 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 probesat the regulator see Figure 231 With the ignition OFF check voltage on the RED sensing BLUE field and BROWN ignition wires in the regulator plug2 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 read3 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 plugCompare your readings with the table at right If readings on RED or BROWNwires do not match values shown check 10amp and 1amp fuses wiring andconnections back to their sources If RED and BROWN match expected readings but BLUE does not unplug and replug fourprong plug and retest If theBLUE wire shows zero voltage and the display is not lit check connections andfusing on the Positive Battery Sense wire Check voltage at the base of thePositive Battery Sense terminal with your test meter 8REGULATOR VOLTAGE TEST CONTINUEDIf voltage is not present on the RED the BROWN and the Positive Battery Sense Wire the regulator will not work If voltage is asexpected at the RED the BROWN and Positive Battery Sense wire and there is zero or an unexpected voltage reading at the BLUEwire 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 alternator The following describes the recommended methods for determining alternator TESTINGTest A The alternator and regulator can be tested for function by determining if a magnetic field exists at the alternators pulley shaftor rear bearing To test1 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 alternator2 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 regulator3 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 properlyTest B If there is little or no magnetic pull at the pulley shaft or at the rear bearing initiate the following test1 With the key off and the engine off remove the large harness plug from the regulator2 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 harness3 Using your steel screwdriver inspect for a magnetic field as described above4 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 Ring properly If no magnetic field is present proceed with the next testTest C Testing the actual output of the alternator is known as Full Field Testing This can be Figure 24 Jumping power wire toaccomplished by jumping a positive 12VDC current to the field terminal at the rear of the alter fieldnator This test eliminates both the regulator and the harness making it easier to isolate your investigation to the alternator CAUTION Ensure that all voltage sensitive equipment is turned off prior to starting the engine Voltage is unregulated during this testand could damage sensitive electronics DO NOT let the engine run any longer than necessary to detect charging If the system isnot charging remove the alternator and have it inspected by a qualified alternator shop or call Balmar for warranty evaluationTo test the alternator1 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 system2 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 occur3 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 present4 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 levelsIf 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 malfunctioning orthere may be a continuity problem Contact our technical support staff at 360 4356100 If you determine that repair service is necessary for either your alternator or regulator please gather the following information before contacting our service technicians1 Make and model of alternator2 Model of voltage regulator and date of mfg date punched on rear side label of regulator3 Voltage readings on red brown and blue wire at regulator with engine off key on4 Voltage readings on red brown and blue wire at regulator with engine running at a fast ideal 1400 rpm 9Suggested Wiring Options SingleDual Outputs 10 Suggested Wiring Options Continued 11 Max Charge MC612 Quick Installation MC612 can be installed with very little difficulty if installation instructions are followed carefully If you are unaccustomedto marine electrical installations we recommend a licensed marine electrician See Page 2 before starting To install1 Mount the regulator in a dry wellventilated location well away from hoses and exhaust manifolds which may cause dam age to the regulator or wiring Avoid areas of heat andor high vibration2 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 harness3 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 polarity4 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 needed5 Attach the Fordtype harness plug to the regulator see illustration The second BLACK ground wire in the harness attach es to the Negative Battery Sense Terminal6 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 12
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