Balmar Ars-5 User manual

ARS-5

MULTI-STAGE

VOLTAGE REGULATOR

INSTALLATION AND OPERATION MANUAL

BALLARD COMMERCIAL INDUSTRIES, INC.

18930 59TH AVE., NE, ARLINGTON, WA 98223

ON THE INTERNET: WWW.BALMAR.NET

Safety Considerations

Always disconnect your battery1.

banks and ensure that switches

are “OFF” prior to installing your

regulator.

Remove loose-tting clothing or 2.

jewelry, which could become en-

tangled in your motor or other ma-

chinery prior to installing regulator.

Wear ANSI-approved safety eye-3.

wear and protective gear.

DO NOT attempt to modify the reg-4.

ulator. Modications could result in

damage to your charging system,

and will void your warranty.

Do not attempt installation if you5.

are tired or fatigued.

Ensure that the engine has cooled6.

before initiating installation.

Do not attempt regulator installa-7.

tion while using alcohol or medi-

cation that could impair your judg-

ment or reaction time.

Always use the right tool for the8.

job. Improper tool use may dam-

age regulator or your vessel, and

could result in personal injury.

Take time to read the manual.9.

Equipment damage and possible

injuries may result from an incom-

plete understanding of the instal-

lation and operation of the ARS-5

regulator. If you are unfamiliar with

marine electrical systems, consult

with a licensed marine electrician.

Introduction

The Balmar ARS-5 provides precise voltage control for Bal-

mar high-output 12-volt alternators and other externally reg-

ulated P-type (positive eld) alternators, the ARS-5 features

user selectable programs for the following battery types: Deep

cycle ooded, gel, AGM and spiral wound (Optima) batteries.

In addition, the regulator features a universal default (UFP)

program that’s safe for most battery types.

In addition to the user selectable preset programs, the ARS-

5 features a wealth of advanced programming modes which

make it possible to tailor charging to a wide variety of environ-

ments and battery types

When used in conjunction with optional MC-TS-A and MC-TS-

B alternator and battery temperature sensors, the ARS-5 fea-

tures the ability to monitor and respond to a range of ambient

temperature conditions, including reduction or discontinuation

of charging voltages, should a catastrophic over-temperature

condition occur at the alternator or the batteries.

Introduction...........................1

Safety Considerations..........1

Regulator Installation........... 2

Unpacking Box .....................2

Locate/Mount Regulator ......2

Basic Wiring Installation...... 2

Regulator Terminal Layout ..3

Installation By Wire ...........4-5

Initial Start Up .......................6

Regulator Operation............. 6

Regulator Display Modes.....7

Using Magnetic Tool.............8

Regulator Programming ......8

Basic Programming..............8

Adjust For Battery Type .......8

Belt Load Manager ...............9

Short/Long Display.............10

Failure Avdisory Mode ....... 11

Advanced Programming.... 11

Unlock Adv. Programming. 11

Adjust Adv. Programs ...... 11-12

Default Program Settings ..12

Add’l. Regulator Features.. 13

Troubleshooting ............14-15

Warranty .............................. 16

- 1 -

CAUTION: The following instructions are intended for use by experienced marine

electrical installers. If you are not experienced at installing electrical system

components, we recommend the use of a qualied marine electrical technician.

Regulator Installation

The following information is intended to provide the installer with the

basic information required to complete installation. This section of the

installation manual will deal with mounting, wiring connections and ba-

sic programming for battery type. Additional information regarding ad-

vanced programming adjustments and troubleshooting are addressed

later in the manual.

Unpacking The Box

Your ARS-5-H regulator kit is packaged with the

following items:

ARS-5 regulator•

54” wiring harness•

Magnetic programming tool•

Installation and operation manual•

If any of the listed items is not included with your regulator kit, call our customer service department at 360-435-6100.

Please note -- if your regulator box is marked ARS-5, without the “H” designation, your kit will not include the wiring har-

ness.

Locate And Mount The Regulator

Choosing a mounting location for your voltage regulator should be deter-

mined based on the following factors; distance from alternator, distance from

inverters, transmitters and other sources of RF noise, convenient access

and readability of the display. The regulator wiring harness is 54 inches long,

providing a three to four foot radius for mounting. Ample airow is essential

for the regulator’s proper operation. Ensure that the regulator is free from

obstructions that restrict air movement around or below the regulator’s alu-

minum heat sink. While the regulator is designed to operate safely in condi-

tions typical of a marine engine compartment, the regulator may be better

protected, and easier to use and monitor if mounted outside of the engine

compartment.

Should it be necessary to install the regulator further than 54 inches from

the alternator, ensure that any wire extensions are properly connected, as

resistance in the harness wiring can affect charging efciency. If harness

length must reach beyond approximately eight feet, replace the RED power

BLACK ground and BLUE eld wires with larger gauge wire that’s sized to

ensure voltage drop < 3%.

Basic Wiring Installation

The regulator’s wiring harness includes ve wires required for standard

installation. Four of those wires are connected to the regulator via a

Ford-style plug connector that’s pre-installed on the regulator. These

wires include the Ground (BLACK), Power (RED), Ignition (BROWN)

and Field (BLUE). Plug is shown at right.

In addition, the harness includes a separate Stator (WHITE) wire. The

proper terminal connection points for this, and additional wiring connec-

tions, are illustrated on the pin location legend shown and discussed on

the following pages.

- 2 -

GROUND INPUT1. - Connects regulator to system

ground via alternator ground terminal. BLACK wire

included in Ford style plug.

POWER INPUT2. - Supplies all power to operate the

regulator, and provides a source of sensing voltage

for the regulator to control charging output. RED wire

included in Ford-style plug.

IGNITION INPUT3. - Connects to a switched source

of battery voltage (to ignition switch or oil pressure

switch). BROWN wire in regulator wiring harness.

FIELD OUTPUT4. - Provides excitation voltage to con-

trol the rate of alternator output based on battery volt-

age. BLUE wire in regulator wiring harness.

BAT. TEMP. (+)5. - For use with optional BATTERY

Temperature Sensor (MC-TS-B). Sensor lug con-

nects to negative battery post, enabling regulator to

monitor and respond to battery temperature condi-

tion. USE CARE TO ENSURE POSITIVE AND NEG-

ATIVE WIRES ARE CONNECTED TO THE APPRO-

PRIATE REGULATOR TERMINAL.

BAT. TEMP. (-)6. - For use with optional Battery Tem-

perature Sensor (MC-TS-B).

STATOR IN7. - Connect to WHITE wire included in regu-

lator wiring harness.

TACHOMETER OUT8. - Connect to tachometer sender

wire when using stator output to provide a signal for

an electric tachometer. NOT REQUIRED when a me-

chanical tachometer is used.

ALT. TEMP. (+)9. - For use with optional Alternator Tem-

perature Sensor (MC-TS-A). Sensor lug connects to

rear case bolt of alternator, enabling regulator to moni-

tor and react to alternator over-temperature condition.

USE CARE TO ENSURE POSITIVE AND NEGATIVE

WIRES ARE CONNECTED TO THE APPROPRIATE

REGULATOR TERMINAL.

ALT. TEMP. (-)10. - For use with optional Alternator Tem-

perature Sensor (MC-TS-A).

DASH LAMP11. - provides a source of ground under the

following conditions: Low charging voltage (<12.7V),

high charging voltage (>15.5V), high alternator tem-

perature (>105°C), high battery temperature (>52°C),

or no stator output (if activated in basic program mode).

500 mA maximum.

ARS-5 Regulator Terminal Layout

- 3 -

Installation By Wire

Install BLACK (#1) Ground Wire

The BLACK Ground Wire (#1 in diagram at right) is included in the four-wire Ford-style plug on the wiring harness and is

factory installed on regulator packages designated with “H” at the end of the model number. The other end of the Ground

Wire is tted with a ring terminal connector. In most applications, this wire can be

connected directly to the alternator’s ground terminal post. Both alternators and

regulators must be connected to system ground.

Install RED (#2) Power Wire

The RED Power Wire (#2 in diagram at right) is included in the four-wire Ford-

style plug and is factory installed on regulator packages designated with “H” at

the end of the model number. The other end of the Power Wire is tted with a ring

terminal connector. In most applications, this wire can be connected directly to

the alternator’s positive output post. When a diode-type battery isolator is used,

the power wire must be connected to the battery side of the battery isolator.

Power Wire is equipped with 10-amp ATC type fuse. The Power Wire must be

fused to ensure against damage to the voltage regulator.

Install BROWN (#3) Ignition Wire

The BROWN Ignition Wire (#3 in diagram at right) provides the ON/OFF voltage

for the regulator. This wire is included in the Ford-style plug at the regulator end

of the wiring harness. The other end of the wire is tted with a butt connector.

Typically, the ignition wire is connected to the ON side of the ignition switch. This

may be at the actual switch, or to the wire in the existing engine wiring loom that

delivers switched voltage from the ignition switch. In some cases, an oil pressure switch may be used to activate the regu-

lator. In either case, the regulator’s ignition wire must see zero volts when the engine ignition is switched off.

Install BLUE (#4) Field Wire

The BLUE Field Wire (#1 in diagram at right) provides regulated current to control alternator output. The wire is included

in the wiring harness Ford-style plug and is pre-connected at the regulator. At the other end of the wire, you’ll nd either

a plug or a ring terminal, depending on the alternator’s eld terminal connection. Attach the eld wire to the alternator’s

eld terminal.

Install Battery Temperature Sensor (#5 Positive, #6 Negative)

The optional Battery Temperature Sensor (MC-TS-B) allows your ARS-5 voltage regulator to monitor your battery bank

for changes in battery temperature, and adjust charging voltages to suit. The MC-TS-B sensor includes a 20-foot cable, a

sensing attachment lug and positive and negative regulator plug-in connectors. To install the MC-TS-B:

Connect sensor lug to the negative post closest to the center of the battery bank. Extend sensor cable to regulator.1.

Connect the positive and negative female connectors to the Battery Temperature Sensor on the regulator (#5 is posi-2.

tive. #6 is negative). It is essential that the terminals match the polarity of the regulator connection pins (red wire to

positive terminal and black wire to negative terminal connectors).

Install WHITE Stator-In (#7) And Tach-Out (#8)

When an electric tachometer is used, the alternator’s stator output will

provide the electrical pulse needed to drive the tachometer. The ARS-5

has been designed to provide regulated tach output when the WHITE sta-

tor wire is connected to the regulator’s Stator In (#7 in diagram) terminal

and the outfeed wire to the electric tachometer is connected to the Tach

Out terminal (#8 in diagram). Stator output can also be used to detect

alternator failure. See Basic Programming information for details.

When connecting the tachometer to the alternator stator output, it will be

necessary to determine the number of poles in the alternator in order to

properly adjust your tachometer. Most Balmar alternators feature 12-pole

rotors and stators, though, in some cases, the pole count may be 14. See

alternator manual for specics. See your tachometer manual for adjust-

ment instructions.

- 4 -

Install Alternator Temperature Sensor (#9 Positive, #10 Negative)

The optional Alternator Temperature Sensor (MC-TS-A) allows your ARS-

5 voltage regulator to monitor your alternator for temperatures in excess

of safe operating levels. The MC-TS-A sensor includes a 54” cable, a

sensing attachment lug and positive and negative regulator plug-in con-

nectors. To install the MC-TS-A:

Connect the sensor lug to the terminal provided (6-Series) or one of 1.

the four bolts that hold the alternator’s front and rear cases together.

Extend sensor cable to the regulator. The cable can be included with-

in the regulator’s wiring harness, or can be run alongside the harness

and attached with cable ties.

Connect the positive and negative female connectors to the Alternator 2.

Temp. Sense terminals on the regulator (#9 is positive. #10 is nega-

tive). It is essential that the terminals match the polarity of the regu-

lator connection pins (red wire to positive terminal and black wire to

negative terminal).

- 5 -

CAUTION: Reversing the polarity of the terminal connections on any of the alternator or battery

temperature sensors can result in invalid sensing and potential damage to alternators, regulator

and/or batteries.

Install Dash Lamp (#11)

The Dash Lamp (#11) terminal provides the ability to activate a visual or

audible indicator when the regulator monitors the following conditions:

Low system voltage, high system voltage, high alternator temperature,

high battery temperature (temperature conditions are only indicated when

appropriate temperature sensors are connected) and no voltage on sta-

tor, indicating that the alternator has failed. When a described condition

is detected, the regulator sends the Dash Lamp terminal from neutral to

ground. To utilize the Dash Lamp function:

Connect a small LED or incandescent lamp, or an audible (piezo) 1.

alert (maximum current ow is 500 mA) to a positive voltage source.

Connect the negative terminal on the lamp or audible alert to the Dash 2.

Lamp terminal on the regulator.

When connected, the lamp should ash at regulator start-up to indi-3.

cate active status.

Magnetic Reed Switch

Looking much like a small thermometer atop

the regulator’s circuit board, the magnetic reed

switch provides a durable, sealed interface that

enables the user to set basic and advanced

regulator programming features. Included with

the regulator is a small screwdriver that doubles

as the regulator’s programming tool. A small

magnet embedded in the tip of the screwdriver’s

handle allows the user to activate the magnetic reed switch. By holding the magnet to the RED dot located at the end of

the reed switch, the user can scroll through the regulator’s various program modes and individual program selections.

360-435-6100 360-435-3210

On the web: www.balmar.net

NOTES:

Magnet

Initial Pre-Flight Test And Start-Up

When the regulator is properly mounted and the regulator wiring is installed, the ARS-5 is ready for pre-ight testing. Be-

fore turning on the engine, it is advisable to check voltages at the following terminal connections to ensure that the wiring

is correct. Test #1 veries proper voltage values with the regulator turned off. Test #2 veries the expected voltages with

the regulator turned on.

Note: If the regulator’s BROWN ignition wire is receiving it’s switched source of voltage from an oil pressure switch, it may

be necessary to start the engine before applying test #2. If the engine must be run to accomplish test #2, be sure that

alternator is properly cabled on both positive and negative sides to the battery being charged. Failure to do so could result

in damage to the regulator and alternator.

Using your hand-held multi-meter, test the following wiring terminals for voltage:

TEST #1: Engine/Ignition Off

Primary RED Power Wire (Terminal #2) >12V•

BROWN Ignition Wire (Terminal #3) 0V•

Primary BLUE Field Wire (Terminal #4) 0V•

TEST #2: Engine/Ignition ON

Primary RED Power Wire (Terminal #2) >12V•

BROWN Ignition Wire (Terminal #3) >12V•

Primary BLUE Field Wire (Terminal #4) 4-12V•

- 6 -

Regulator Operation

The ARS-5 regulator’s microprocessor controlled charging system uses a sophisticated, multi-stage prole to deliver

optimal charging, while protecting the batteries from overcharging damage. When the regulator is rst turned on, the pro-

cessor performs a quick one-second self diagnostic assessment. Following that diagnostic, the ARS-5 initiates a charge

program as follows:

Start Delay - Factory set at one second. Can be user-adjusted to a maximum of 999 seconds in the regulator’s ad-1.

vanced programming mode. See Advanced Programming section for adjustment instructions.

Soft Ramp - Gently increases voltage to bulk preset levels based on battery program selected.2.

Bulk Charge - The most aggressive of the charging stages. Voltage is held at a pre-set level, specied by battery 3.

program selected, for a set time period. Factory-set bulk time is 18 minutes. Adjustable in 1/10-hour increments.

Calculated Bulk Charge - Holds voltage at bulk level for six minutes, then calculates system condition by comparing 4.

existing voltage, time at voltage, and eld percentage to target values. If values are met, the regulator advances to

the next stage. If values are not met, the regulator continues to bulk charge and compares real-time to target values.

The regulator will continually update calculations

until all values are met.

Ramps down to Absorption voltage.5.

Absorption Charge - Regulator continues to 6.

control the alternator’s output voltage for an ad-

ditional 18 minutes at approximately 2/10-volts

below bulk charging voltage. Adjustable in 1/10-

hour increments.

Calculated Absorption Charge - Holds voltage at 7.

absorption level for six minutes, then calculates

system condition bycomparing existing voltage, time at voltage, and eld percentage to target values. If values are

met, the regulator advances to the next stage. If values are not met, the regulator extends the absorption charge

and compares real-time to target values. The regulator will continually update calculations until all values are met.

Ramp down to Float.8.

Float Charge - Regulator continues to control the alternator’s output voltage for an additional 18 minutes, typically at 9.

one volt less than bulk voltage (based on battery program presets). After that initial xed time period, the regulator

can respond to increased charging demand by cycling to absorption voltage. After 12 hours of continuous operation,

the regulator will automatically revert to absorption voltage through calculated absorption and back to oat charging

stage.

- 7 -

Regulator Display Modes - Short Display/Long Display

The regulator’s three digit alphanumeric LED display provides a scrolling view of charging status. Under normal operation,

the display will indicate the following:

Indicates Balmar.

Indicates Model ARS-5

Indicates regulator’s default Universal Factory Program. Display will vary based on program selected.

Indicates the regulator’s Belt Load Manager setting. Ranges from b-0 to b-9.

Indicates stage of charge. “b” indicates bulk. “A” indicates absorption. “F” indicates oat.

Indicates system Battery Voltage. Followed by actual voltage reading.

Indicates Calculated voltage (target voltage based on preset program levels). Followed by voltage reading.

Indicates Battery temperature. Followed by NC (not connected), or temperature in celsius.

Indicates Alternator temperature. Followed by NC (not connected), or temperature in celsius.

In addition to the information provided in the basic display shown above, the ARS-5 long display provides the following

data. The long display is accessed during basic programming, which will be discussed in the next section of the manual.

Indicates the percentage of eld output to the alternator. The higher the percentage, the greater the output.

Indicates regulator’s software revision code.

Indicates regulator circuit board temperature. Followed by degrees celsius.

Indicates, in millivolts per degree C per cell, voltage compensation for battery temperature.

Indicates overall regulator hours. Followed by hours (by tenths) and hours in excess of 100.

Indicates eld threshold; bulk to absorption to oat. Factory set at 65%. Adjust in Advanced Programming.

Indicates eld threshold from oat to absorption. Factory set at 65%. Adjust in Advanced Programming.

Indicates system advisory codes. Individually numbered codes are dened below.

The following advisory codes can be used to determine possible system errors or to identify specic operational modes.

Note that E codes are cumulative and will be held in memory until cleared. Codes can be cleared by entering dSP and

letting it save. Display settings DO NOT need to be changed. See basic programming for more info.

BATTERY TEMP. SENSOR CABLE

SHORTED

BATTERY TEMP. SENSOR CABLE

OPEN OR NOT FOUND

ALTERNATOR TEMP. SENSOR

CABLE SHORTED

ALTERNATOR TEMP. SENSOR

CABLE OPEN OR NOT FOUND

BATTERY EXCEEDS 55˚C.

FACTORY DEFAULT

ALTERNATOR TEMPERATURE

EXCEEDS 107˚C

VOLTAGE REGULATOR

EXCEEDS 90˚C

BATTERY VOLTAGE BELOW

12.5 VOLTS

BATTERY VOLTAGE BELOW

10.5 VOLTS

BATTERY TEMP EXCEEDS

USER ADJUSTED VALUE

BATTERY VOLTAGE

EXCEEDS 16 VOLTS

FIELD VOLTAGE TOO HIGH.

STATOR VOLTAGE TOO HIGH.

SMALL ENGINE MODE IS IN

OPERATION

BELT LOAD MANAGER IS IN

OPERATION

BAL

E10 E40

-b-

E14

E34

E52

UFP

E24

E42

FFL

A-5

r3.8

E11

E22

E41

FbA

E15

E20 E35

b-0

SLP

E30

E51

- 8 -

Regulator Programming Modes

Using The Magnetic Reed Switch

Access to the ARS-5 regulator’s basic and advanced programming modes is provid-

ed by a magnetic reed switch located in the upper left corner of the regulator’s circuit

board. The reed switch provides selectable control of the regulator’s programming

without creating an intrusion point as is common on many other adjustable voltage

regulators currently on the market.

A small screwdriver with a magnet embedded in the tip of the handle is included to

activate the magnetic reed switch. While any magnetic tipped tool can be used, the

Balmar programming screwdriver does an excellent job as an interfacing tool.

Programming is accomplished by contacting and removing the magnet from the RED

dot afxed to the regulator’s epoxy potting. If the magnet has difculty activating the

reed switch at that position, try moving the up and down along the length of the reed

switch until the RED LED dot is illuminated at the top of the LED display, between

the second and third display digits. The RED light indicates activation of the the reed

switch.

Within the basic and advanced programming instructions, activation of the reed switch will be described by the following

actions:

TOUCH / RELEASE - Indicates the action of contacting and immediately removing the magnet from the reed•

switch

TOUCH / HOLD - Indicates the action of contacting and holding the magnet to the reed switch•

TOUCH / HOLD / RELEASE - Indicates the action of contacting and holding the magnet to the reed switch,•

then releasing the reed switch be removing the magnet from the RED dot on the epoxy potting

Basic Programming

Programming For Battery Type

The ARS-5 features selectable programs for the following battery technologies; Universal Default (UFP), Deep Cycle

Flooded (FdC), gel (gEL), AGM (AgL), and Optima spiral wound batteries (OPS). Programming can be done whenever the

regulator is active. System voltage must be greater than 12.5V for programming changes to be saved.

When activating the programming mode, keep in mind that the regulator will scroll through the basic programming mode

three times before saving and returning to the operational mode. To adjust the regulator for your battery type:

Turn on the regulator. This may be accomplished by turning the ignition switch at the panel to the ON position. If the 1.

regulator’s BROWN ignition wire is connected to an oil pressure switch, it may be necessary to start the engine to

activate the regulator.

Once the regulator is on and the display is scrolling, TOUCH / HOLD the magnetic end of the programming screw-2.

driver to the RED dot on the regulator as described above.

Continue to hold the magnet to the RED dot. The letters PRO will appear on the LED.3.

Continue to hold the magnet to the RED dot. The letters BA will appear on the LED.4.

Continue to hold the magnet to the RED dot. The LED display will begin to scroll through the various battery codes.5.

When the desired battery code is displayed, RELEASE the magnet from the RED dot.6.

The display will indicate BA once again. At this point, you have the option to re-enter the battery type mode by re-7.

applying the magnet to the RED dot. Otherwise, the display will cycle to bEL, indicating entry into the Belt Load Man-

ager mode.

INDICATES ENTRY INTO BASIC

PROGRAMMING MODE

INDICATES ENTRY INTO BATTERY

TYPE PROGRAM MODE

INDICATES FACTORY DEFAULT

UNIVERSAL FACTORY MODE

INDICATES PROGRAM FOR DEEP

CYCLE FLOODED BATTERIES

INDICATES PROGRAM FOR DEEP

CYCLE GEL BATTERIES

INDICATES PROGRAM FOR AB-

SORBED GLASS MAT BATTERIES

INDICATES PROGRAM FOR

SPIRAL WOUND (OPTIMA)

gE.L

Pr.o

Ag.L

bA.

bE.L

OP.S

UF.P

Fd.c

INDICATES ENTRY INTO THE REGULATOR’S BELT LOAD MANAGER MODE.

- 9 -

Basic Programming

Programming The Belt Load Manager

The ARS-5 provides the ability to manage regulator eld potential, making it possible to govern the horsepower loads

placed on the drive belt(s) by the alternator. The Belt Load Manager can also be used to protect the alternator from extraor-

dinary load created by a battery load that’s too large for the alternator’s capacity. The Belt Load Manager is accessed in

the basic programming mode, directly after the battery type programming mode. The Belt Load Manager can be accessed

at the same time the battery program is set, or by itself. To program the Belt Load Manager

When activating the programming mode, keep in mind that the regulator will scroll through the basic programming mode

three times before saving and returning to the operational mode. To adjust the regulator for your battery type:

Turn on the regulator. This may be accomplished by turning the ignition switch at the panel to the ON position. If the 1.

regulator’s BROWN ignition wire is connected to an oil pressure switch, it may be necessary to start the engine to

activate the regulator.

If the battery type program has been adjusted, TOUCH / HOLD when entry into the Belt Load Manager is indicated by 2.

the bEL display on the regulator’s LED.

If you don’t wish to adjust the battery programming, TOUCH / HOLD the RED dot when the regulator is activated. 3.

RELEASE when the Pro display is indicated. The regulator will indicate bA, for battery type, and will cycle to bEL.

TOUCH / HOLD. The regulator display will indicate b-0 (indicating that the Belt Load Manager is off). Continue to 4.

HOLD. The regulator display continue to scroll through nine settings. Each setting decreases the eld potential by

approximately ve percent.

RELEASE when the display indicates your desired level of eld reduction. The display will cycle to bEL. You can re-5.

activate to change your selection, or wait until the regulator cycles to the next programming mode.

The display will cycle to dSP, indicating the selection mode where the user can toggle between a short or long dis-6.

play.

INDICATES ENTRY INTO BELT

LOAD MANAGER MODE

INDICATES BLM SETTING #1.

FIELD REDUCTION 5%.

INDICATES BLM SETTING #2.

FIELD REDUCTION 10%.

INDICATES BLM SETTING #3.

FIELD REDUCTION 15%.

INDICATES BLM SETTING #4.

FIELD REDUCTION 20%.

INDICATES BLM SETTING #5.

FIELD REDUCTION 25%.

INDICATES BLM SETTING #6.

FIELD REDUCTION 30%.

INDICATES BLM SETTING #7.

FIELD REDUCTION 35%.

INDICATES BLM SETTING #8.

FIELD REDUCTION 40%.

INDICATES BLM SETTING #9.

FIELD REDUCTION 45%.

b-.1b-.4b-.7

b-.2b-.5b-.8

b-.3b-.6b-.9

bE.L

Programming For Short Or Long Display Mode

You can choose the amount of information displayed on the regulator. The information displayed on the short or long dis-

play is detailed on Page 7 of the manual. To adjust the regulator for short or long display:

TOUCH / HOLD when entry into the short/long display selector is indicated by dSP on the regulator’s LED.1.

The regulator display will indicate codes Sd (for short display) or Ld (for long display). 2.

RELEASE when the display indicates your desired display mode. The display will cycle to dSP. You can re-activate to 3.

change your selection, or wait until the regulator cycles to the next programming mode.

INDICATES ENTRY INTO SHORT

OR LONG DISPLAY MODE

INDICATES END OF BASIC PROGRAMMING MODE

INDICATES SHORT

DISPLAY MODE

INDICATES LONG

DISPLAY MODE

dS.P

--.-

Sd.

Programming For Alternator Failure Advisory Mode (BDL)

The regulator provides a ground signal on the dash lamp terminal when the following conditions occur: low battery volt-

age (<12.7V), high battery voltage (>15.5V), high battery temperature (>52˚C), or high alternator temperature (105˚C). In

addition, the user has the option to send the dash lamp to ground in the event that the stator output drops to zero volts.

The Regulator’s Default bdL setting is ON. Monitoring stator output is an optional function which can be turned on or off

in the basic programming mode. The regulator’s default setting for the bdL mode is ON, meaning that the stator output is

being monitored. This function can be used in conjunction with a relay to control a charge indicator lamp.

To enable or disable the stator monitoring function, activate and hold when the bdL mode is indicated. Release when the

desired setting is shown. NOTE: Stator wire must be connected to the regulator’s Stator-In terminal to use this function.

Ld.

INDICATES ENTRY INTO ALTERNA-

TOR FAILURE ADVISORY MODE

STATOR OUTPUT

MONITORING OFF

STATOR OUTPUT

MONITORING ON

bdL OFF On

- 10 -

Notes:

- 11 -

Advanced Programming

Accessing The Advanced Programming Mode

The ARS-5 provides a broad range of advanced user adjustments in its password-protected Advanced Program mode.

The Advanced Program mode is accessed via the Basic Program mode. To access the Advanced Program mode:

With the regulator activated, TOUCH / HOLD the magnet to the RED dot on the regulator’s epoxy potting.1.

The regulator will cycle to PRO. RELEASE the magnet from the switch.2.

The regulator will cycle through all of the Basic Program modes; bA, bEL, Ab2, dSP and bdL -- followed by three dashes.3.

TOUCH / HOLD when the three dashes are displayed. The dashes will be replaced by AP0 followed by AP1, and so on.4.

When the display indicates AP5, RELEASE.5.

The display will cycle to PrA, indicating entry into the Advanced Programming mode.6.

INDICATES ENTRY INTO PRO-

GRAM MODE

INDICATES SELECTION MODE

FOR BATTERY TYPE

INDICATES SELECTION MODE

FOR BELT LOAD MANAGER

INDICATES SELECTION MODE

FOR SHORT/ LONG DISPLAY

INDICATES END OF BASIC

PROGRAM MODE

INDICATES ENTRY INTO PASS-

WORD MODE FOR AP MODE

INDICATES ENTRY INTO PASS-

WORD MODE FOR AP MODE

INDICATES PASSWORD FOR AD-

VANCED PROGRAM MODE

INDICATES ENTRY INTO THE AD-

VANCED PROGRAM MODE

Advanced Programming Modes

Making Advanced Programming Adjustments

Once accessed, the Advanced Program mode allows the user to adjust time, voltage and temperature settings for most

operational modes. When the desired mode is indicated, TOUCH / HOLD the magnet to the RED dot on the epoxy pot-

ting. When the reed switch is engaged, the values for the various modes will scroll upward or downward. To reverse the

direction of scroll:

REMOVE the magnet from the reed switch.1.

Wait for the mode indicator to be displayed.2.

TOUCH / HOLD when the mode indicator is displayed. The values for that mode will begin to scroll in the opposite 3.

direction. Continue to HOLD until the desired value is displayed.

REMOVE the magnet from the RED dot. The mode indicator will be displayed again, followed by the indicator for the 4.

next Advanced Programming mode. The Advanced Programming Modes are as follows:

Start Delay. Controls time from regulator activation to start of charging. Factory preset at one second.

Adjustable to a maximum of 999 seconds. To reverse direction of scroll, release magnet and wait for LED

to display dLc code. Re-activate switch with magnet and release when desired value is indicated.

Advanced Program Mode. Once the correct password is used to unlock the Advanced Program

mode, the PrA display will be immediately followed by Advanced Programming modes. The Advanced

Programming modes include:

Compensation Limit. Controls maximum allowable temperature compensated system voltage. Ad-

justment spans from 14.1 to 15.9 volts. Default is 14.8V. To reverse direction of scroll, release magnet and

wait for LED to display CL code. Re-activate switch and release when desired value is indicated.

High Voltage Alarm. Allows user to set the voltage required to activate an alarm. Default value is one

volt above bulk charging voltage.

Bulk Voltage. Controls the target voltage for bulk charge mode. Starts at value set by battery program

in use. Adjustment spans from 14.1 to 14.8 volts. To reverse direction of scroll, release magnet and wait

for LED to display bv code. Re-activate switch and release when desired value is indicated.

Bulk Time. Controls time setting for bulk mode. Standard value set is 18 minutes. Settings are from 6

minutes to 6 hours. To reverse direction of scroll, release magnet and wait for LED to display b1c code.

Re-activate switch with magnet and release when desired value is indicated.

Pr.o

Pr.A

dL.c

AH.L

CL.

bv.

b1.c

Av.

A1.c

dS.P

AP.5

bE.LPr.A

bA.

--.-

Absorption Voltage. Controls the target voltage for absorption charge mode. Starts at value set by

battery program in use. Adjustment spans from 13.9 to 14.7 volts. To reverse direction of scroll, release

magnet and wait for LED to display Av code. Re-activate and release when desired value is indicated.

Absorption Time. Controls time setting for absorption mode. Standard value set is 18 minutes. Set-

tings are from 6 minutes to 6 hours. To reverse direction of scroll, release magnet and wait for LED to

display A1c code. Re-activate switch with magnet and release when desired value is indicated.

AP.1

bd.L

- 12 -

Alternator Temperature Threshold. Controls the setpoint at which point eld current is reduced

when the the alternator temperature sensor indicates an over-temp condition at the alternator. Requires

temperature sensor installation. Preset at 108˚.

Float Voltage. Controls the target voltage for oat stage. Adjustment spans from 13.0 to 13.8 volts.

Default is based on battery program selected. To reverse direction of scroll, release magnet and wait for

LED to display Fv code. Re-activate switch and release when desired value is indicated.

Float Time. Controls time setting for oat mode. Standard value set is 18 minutes. Settings are from 6

minutes to 12 hours. To reverse direction of scroll, release magnet and wait for LED to display F1c code.

Re-activate switch with magnet and release when desired value is indicated.

Low Voltage Alarm. Allows the user to set the trigger voltage for the low voltage alarm. Default set-

ting for the Low Voltage Alarm is 12.7 volts.

Field Threshold - Float To Absorption . Controls the criteria used to determine the eld current

threshold required to cycle between oat and absorption charging modes. Factory set at 65%. Raising

“FFL” increases calculated oat charge time. Adjusted in 1% increments. Span of adjustment is 16% to

96%. To reverse direction of scroll, release “FFL” code. Reactivate switch with magnet and release when

desired value is indicated.

Field Threshold - Bulk To Absorption To Float . Controls the criteria used to determine eld

output required to maintain calculated charging mode. Factory set at 65% eld output. Raising “FbA”

shortens calculated bulk charge time. Lowering “FbA” increases calculated bulk charge time. Span of ad-

justment is 16% to 96%. To reverse direction of scroll, release magnet and wait for LED to display “FbA”

code. Re-activate switch and release when desired value is indicated.

Slope Voltage Correction. Adjusts the voltage (in milivolts) the regulator uses when monitoring

battery temperature sensing. Can be custom adjusted to meet the needs of unique battery technologies.

Consult with battery manufacturer for specic slope voltage recommendations.

Battery Temperature Threshold. Controls the setpoint at which point eld current is discontinued

when the the battery temperature sensor indicates an over-temp condition at batteries being sensed.

Requires temperature sensor installation. Preset at 52°C.

Default Program Settings By Battery Type

UFP FDC GEL AGM OPS

START DELAY (SECS.) 1 1 1 1 1

SOFT RAMP (SECS.) 60 60 60 60 60

BULK VOLTAGE 14.1 14.6 14.1 14.38 14.6

BULK TIME (MINIMUM) 18 MIN 18 MIN 18 MIN 18 MIN 18 MIN

ABSORPTION VOLTS 13.9 14.4 13.9 14.18 14.4

ABSORPTION TIME (MINIMUM) 18 MIN 18 MIN 18 MIN 18 MIN 18 MIN

FLOAT VOLTS 13.4 13.4 13.7 13.4 13.4

FLOAT TIME (MINIMUM) 18 MIN 18 MIN 18 MIN 18 MIN 18 MIN

FLOAT TIME (MAXIMUM) 12 HRS. 12 HRS. 12 HRS. 12 HRS. 12 HRS.

HIGH VOLTAGE ALARM (VOLTS) 15.2 15.6 15.1 15.38 15.6

LOW VOLTAGE ALARM (VOLTS) 12.7 12.7 12.7 12.7 12.7

MAX BAT. TEMP. 125˚F/52˚C 125˚F/52˚C 125˚F/52˚C 125˚F/52˚C 125˚F/52˚C

MAX ALT. TEMP. 226˚F/108˚C226˚F/108˚C226˚F/108˚C226˚F/108˚C226˚F/108˚C

Fv.

Fb.A

F1.c

AL.L

FF.L

AL.1

SL.P

B1.L

- 13 -

Additional Regulator Features

Small Engine Mode

In situations where additional power is needed for propulsion, the ARS-5 provides the option to manually reduce regula-

tor eld output by approximately one half. This option, called Small Engine Mode, can be accessed by creating a direct

pathway between the positive and negative Alternator Temperature Sensor terminals. This

can be done by splicing into the positive and negative wires of the Alternator Temperature

Sensor cable (MC-TS-A) with a switched wire. With the switch in the OFF position, the

Alternator #1 Temperature Sensor will work normally. With the switch in the ON position,

the regulator will reduce eld output by approximately 50%.

To enable the Small Engine Mode:

If the Alternator Temperature Sensor cable is being used, replace the female termi-1.

nal connectors on the cable with Multi-Stack Connectors (Ancor Part # 230612).

Install a standard ON/OFF switch in a location that’s easily reached from the helm.2.

Run wires from the switch back to the positive and negative terminals of the Alterna-3.

tor Temperature Sensor terminals.

Add appropriate connectors to the switched wires and connect to the positive and 4.

negative terminal connections.

Dash Lamp

The ARS-5 provides a Dash Lamp circuit that’s capable of providing a signal to a user supplied and installed audible or

visual alert if the following issues were to occur while the regulator is in operation;

Low Battery Voltage <12.7V•

High Battery Voltage >15.5V•

High Alternator Temperature >226• ˚F/ 108˚C (Requires installation of MC-TS-A sensor.) Temperature adjustable.

High Battery Temperature >125• ˚F/52˚C (Requires installation of MC-TS-B sensor cable.)

Alternator Failure (No voltage on stator).•

NOTES:

- 14 -

System Troubleshooting

Regulator Troubleshooting

The majority of charging difculties can be attributed to damage, corrosion or wear at wiring, fusing or wiring connec-

tions. Before attempting to troubleshoot alternator or regulator issues, be sure to address the following:

Remove and clean all charging system electrical 1.

connections (positive and negative). Check the volt-

age regulator’s harness for continuity. Wires and

terminals can and will become corroded, and need to

be cleaned or replaced. Ensure that the regulator’s

ground wires are provided with a clean connection to

system ground.

Inspect and replace 10A ATC type fuse in the regula-2.

tor wiring harness if fuse appears to be damaged or

corroded. Ensure that the fuse holder is also free of

corrosion.

Charge all batteries to their proper fully charged state, 3.

and determine if they are serviceable. If your batteries

are ooded-type, use your hydrometer to determine

their condition.

Check and tighten alternator belt. If the belt show signs of wear or damage, replace it. Always replace existing belts 4.

with the nest quality replacements available.

If batteries and wiring are in suitable condition, use the tests on the following page to determine if charging problems are

a result of a faulty alternator or regulator. These tests provide an opportunity to isolate the alternator, regulator and wir-

ing harness in order to determine the problem source. In order to perform these tests, you will need an independent DC

meter (preferably 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 battery hydrometer with a thermometer are also helpful diagnostic tools.

Voltage Regulator Testing

Set your voltmeter to 12VDC and connect the negative lead to the BLACK ground wire at the regulator as shown at in the

diagram at right.

With the ignition turned OFF, check voltage on the RED (power), BLUE (eld) and BROWN (ignition) wires in the regulator

plug.

Voltages should be as follow:

RED wire equal to battery voltage•

BLUE wire zero volts•

BROWN wire zero volts•

With the ignition in the ON position (engine not running), check voltage on the RED (power), BLUE (eld) and BROWN

(ignition) wires in the regulator plug:

RED wire equal to battery voltage•

BLUE wire between 4V and 11V•

BROWN wire equal to battery voltage•

PLEASE NOTE: In systems where the ignition (BROWN) wire is supplied power via an oil pressure switch, jump directly

from test #1 to test #3.

With the ignition in the ON position (with engine running at 1,400 rpm fast idle), check voltage on the RED (power), BLUE

(eld) and BROWN (ignition) wires in the regulator plug. Voltages should be as follow:

RED wire equal to battery voltage•

BLUE wire between 4V and 11V•

BROWN wire equal to battery voltage•

- 15 -

If voltage is not present on the RED, the BROWN and the Positive Battery Sense Wire, the regulator will not work. If volt-

age 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) 435-6100, or e-mail us at balmar@balmar.net.

If all voltages at the regulator meet expectations, yet the alternator is not producing charging current, test the alternator.

The following tests are recommended for determining alternator functionality.

Alternator Testing

TEST #1- The following test is used to isolate the alternator and determine if the failure is a result of the alternator. Once

again, testing at either the alternator or regulator is only effective if the wiring, fusing and batteries have been determined

to be in correct working order. The alternator and regulator can be tested for function by determining if a magnetic eld

exists at the alternator’s pulley shaft or rear bearing. To test:

With the ignition in the OFF position, place the tip of a non-magnetic steel screwdriver near the nut on the pul-•

ley shaft or near the rear bearing of the alternator. There should be no evidence of a magnetic eld pulling the

screwdriver toward the alternator. (A slight amount of magnetism may be present, due to residual voltage in the

alternator.)

Engage the ignition, without starting the engine, to activate the voltage regulator. If an oil pressure switch is used, •

a jumper between the RED and BROWN wires in the Ford-style plug will activate the regulator.

After allowing time for the regulator’s start-up delay, place the head of a steel screwdriver near the nut on the •

pulleyshaft or near the rear bearing of the alternator. There should be substantial magnetic pull. If a magnetic

eld is present, the voltage regulator, alternator brushes and rotor are likely to be working properly.

If there is little or no magnetic pull at the pulley shaft or at the rear bearing, initiate the following test:

With the key off and the engine off, remove the large harness plug from the regulator.

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. This bypasses the regulator and tests the alternator and the har-

ness.

Using your steel screwdriver, inspect for a magnetic eld as described above.•

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 magnetism is pres-

ent, the alternator is likely to be malfunctioning.

If a magnetic eld is present. Both harness and alternator brushes and ro-•

tor appear to be working properly. If no magnetic eld is present, proceed

with the next test.

Testing the actual output of the alternator is known as “Full Field Testing”. This can

be accomplished by jumping a positive 12VDC current to the eld terminal at the

rear of the alternator. This test eliminates both the regulator and the harness, mak-

ing it easier to isolate your investigation to the alternator.

CAUTION: Ensure that all voltage sensitive equipment is turned off prior to start-

ing 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 charg-

ing. If the system is not charging, remove the alternator and have it inspected by a

qualied alternator shop, or call Balmar for warranty evaluation.

To test the alternator:

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.

Disconnect the eld wire from the rear of the alternator and attach the other end of the jumper wire to the alterna-•

tor’s Field terminal (F). 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.

- 16 -

The regulator is now bypassed. When the ignition is engaged and the motor is started, the voltage should rise and

charging current should be present.

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 alterna-

tor fails to generate voltage during eld testing, a malfunction of the alternator is likely. Contact your local alternator

repair shop or Balmar’s technical service staff for recommendations.

Conclusion

If your readings differ substantially from the “Expected Readings” listed in the troubleshooting charts, the regulator may

be malfunctioning, or there may be a continuity problem. Contact our technical support staff at (360) 435-6100. If you

determine that repair service is necessary for either your alternator or regulator, please gather the following information

before contacting our service technicians: Make and model of alternator. Model of voltage regulator and date of mfg. (date

punched on rear side label of regulator). Voltage readings on red, brown and blue wire at regulator with engine off, key on.

Voltage readings on red, brown and blue wire at regulator with engine running at a fast ideal 1400 rpm.

LIMITED PRODUCT WARRANTY

BALMAR warrants to the original consumer/purchaser the product is free from any defects in material or workman-

ship 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 verication 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 re-

pair, alteration, modication, or unreasonable use of the products resulting in breakdown, cracked or broken cases nor

are parts damaged by re, 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 identication 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

efciently, BALMAR asks that prior to returning a defective product for repair, you call their customer service depart-

ment for a warranty return authorization number. If factory service is required, you can contact our BALMAR Customer

Service Department Monday through Thursday, 7:30 AM to 5:30 PM, (PST)1-360 435-6100 ext “3”. Material required

for the repair or replacement for the defective part or product is to be supplied free of charge upon delivery of the

defective regulator to BALMAR, 18930 59 Ave. NE, Arlington, WA 98223. Customer is responsible for all return trans-

portation charges and any air or rush delivery expense. BALMAR reserves the right to determine whether to repair

or replace defective components.

THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW

LONG AN IMPLIED WARRANTY LASTS. NO PERSON, AGENT, DEALER IS AUTHORIZED TO GIVE ANY WAR-

RANTY.

BALMAR 19009 61st Ave. NE, Arlington, WA 98223 Phone: (360) 435-6100, Fax: (360) 435-3210 E-mail: balmar@balmar.net, Web: www.balmar.net

For more information, contact Balmar Customer Service or Technical Support at 360-435-6100 or visit the Balmar website at www.balmar.net. Ballard

Commercial Industries, Inc. (Balmar) believes all information herein to be factual and accurate, yet maintains no liability for factual or typographic error.

In addition, Balmar retains the right to revise or update products without notication. Visit the Balmar website for product updates or bulletins that may