Balmar Max charge mc-624 Setup guide

- 1 -

I. INTRODUCTION

The microprocessor-controlled Max Charge

MC-624 is the most advanced regulator avail-

able. Designed to continually monitor battery

voltage and automatically optimize charging, the

MC-624 uses up to 12 time and voltage increments to

ensure your batteries receive a full charge quickly and safe-

ly.

The MC-624 lets you choose from a variety of selectable preset

programs to best suit your charging needs. Its Universal Factory

Program allows you to connect the MC-624 to your alternator right out of the box. Six additional preset programs sup-

port most popular battery types, including standard and deep-cycle flooded batteries, AGM, gel, and Optima (spiral wound)

technologies. An easy-to-use magnetic reed switch delivers quick, precise regulator adjustment. Should your charging system

require individualized adjustment, the MC-624 provides additional user-defined programming options.

When used with optional alternator and battery temperature sensors, the MC-624 automatically monitors ambient tempera-

tures and compensates for over-temperature conditions by reducing field output. Alarm outputs connect to audible or visual

alarms to warn of dangerous system conditions.

II. SAFETY CONSIDERATIONS

Before installing your MC-624 marine regulator, please take a moment to consider

these guidelines for safe regulator installation. Failure to work safely could result in

personal injury or damage to your electrical system.

1. Always disconnect your battery banks and ensure that switches are “OFF”

prior to installing your regulator.

2. Remove loose-fitting clothing or jewelry, which could become entangled in

your motor or other machinery.

3. Wear ANSI-approved safety glasses.

4. DO NOT attempt to modify the regulator. Alterations could result in damage to

your charging system, and will void your warranty.

5. Do not attempt installation if tired or fatigued.

6. Ensure the engine has cooled before initiating installation.

7. Do not attempt installation while using alcohol or any medication that could

impair your judgment or reaction time.

8. Always use the right tool for the job. Improper tool use may damage the regu-

lator or your boat, and could result in personal injury.

9. Take time to read the manual. Equipment damage and possible injuries may

result from an incomplete understanding of the installation and operation of the

MC-624 regulator. If you are unfamiliar with marine electrical systems, consult

with a licensed marine electrician.

TABLE OF CONTENTS

I. Introduction

II. Safety Considerations

III. Basic Installation

IV. Alarm and Sensor Installation

V. Short Display (SD)

VI. Preset Battery Programming

VII. Long Display (LD)

VIII. Advanced Programming (AP)

Amp Manager

Equalization

Advisory / Diagnostic Codes

IX. Troubleshooting

CAUTION

The following instructions are intend-

ed for use by experienced marine

electrical installers. If you are not

experienced at installing electrical

system components, we recommend

the use of a qualified marine

electrical technician.

!"#$"%&19009 61st Ave. NE, Arlington, WA 98223 PHONE: (360) 435-6100

FAX: (360) 435-3210 E-MAIL: balmar@balmar.net WEB: www.balmar.net

Max Charge MC-624

Installation and Operator’s Manual

III. BASIC INSTALLATION

The MC-624 is shipped with either a Port or Starboard harness. If the wiring needs

to be extended beyond the length of the harness, marine grade 12AWG

(American Wire Gauge) wire should be used.

03-00 Rev. # 3.01

To install the regulator:

1. Mount the regulator in a dry, well-ventilated location, well

away from hoses and exhaust manifolds which may cause

damage to the regulator or wiring. Avoid areas of heat

and/or high vibration.

2. Attach the Ford-type harness plug to the regulator (see

Figure 1).

3. The RED wire (in the harness) powers the regulator.Attach

at the positive output terminal at the alternator. If an isola-

tor is used, this wire must be located on the battery side of

the isolator. On a 24V system, this wire can carry 8 amps

and must be protected by a 10-amp fuse. A fuse is includ-

ed with the wiring harness.

3. The BROWN (ignition) wire activates the regulator when

+24VDC is applied to the system.Attach the BROWN wire

to a switched +24VDC source. The auxiliary side of the

ignition switch, or an independent (ungrounded) oil pres-

sure switch are both acceptable connection points. A tog-

gle switch may be added to this circuit to shut down

the alternator load in cases where maximum propul-

sion is needed.

5. The BLACK (ground) wire in the harness attaches to

the System Ground Terminal. The BLACK wire

attaches to preferred ground terminal on the alterna-

tor. A (user supplied) ground strap between the alter-

nator and the preferred ground at the engine is also

strongly recommended.

6. Plug duplex connector with BLUE (field) and

ORANGE (stator) wires into rear of alternator.

7. An AC tap wire for the tachometer can be utilized by

splicing into the ORANGE stator wire with a wire

connecting to the AC tap terminal at the tachometer.

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Figure 1 -

Regulator wiring attachment.

Figure 3 - Regulator terminal layout and function description.

Length 10 Ft. 15 Ft. 20 Ft. 25 Ft. 50 Ft 75 Ft. 100 Ft.

Amps

25 10 8 8 6 4 2 1

50 8 6 4 4 1 2/0 3/0

75 6 4 2 2 2/0 3/0 4/0

100 4 2 2 1 3/0 4/0

125 4 2 1 1/0 3/0 4/0

150 2 1 1/0 2/0 4/0

175 2 1/0 2/0 3/0

200 2 1/0 2/0 3/0

225 1 2/0 3/0 4/0

250 1 2/0 3/0 4/0

275 1/0 2/0 4/0

300 1/0 3/0 4/0

325 1/0 3/0 4/0

350 2/0 3/0

375 2/0 4/0

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IV. ALARM AND SENSOR INSTALLATION

Alternator Temperature Sensor

(MC-TS-A) - Optional

The Alternator Temperature Sensor enables the regu-

lator to sense when the alternator temperature exceeds

safe working limits. The MC-624 responds by reducing

the field current at the alternator and activating the

alarm output. To install the Alternator Temperature

Sensor:

1. Attach the positive and negative wires to the

Alternator Temperature Sensor terminals on the

MC-624 (See Figure 4). See Figure 3 on previ-

ous page for pin locations. Observe proper polar-

ity at the terminals.

2. Attach the heavy lug terminal to a location

described below on your alternator. Flat wash-

ers 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) 5/32" Allen bolts,

install probe, re-secure bolt. (See Figure 5.)

MID CASE MOUNT - Large Case Alternator - Remove (1) of (4) 3/16" Allen bolts,

install probe, re-secure bolt.

Caution: The alternator temperature sensor is not meant to be used as a method to main-

tain alternator temperature. Optional temperature sensors are not a guarantee of protection

against damage from overheat conditions. Inspect your system as quickly as possible if the

sensor alarm is activated. Have your system inspected if overheating occurs.

Battery Temperature Sensor (MC-TS-B) - Optional

When equipped with the optional Battery Temperature Sensor, the MC-624 will auto-

matically compensate for variation above and below normal ambient temperatures. The

MC-624 is equipped with dual battery sensors to enable sensing at two separate bat-

teries. To ensure proper operation, be sure the battery terminals are completely clean

and free of corrosion prior to installation. To install:

1. Secure the 3/8" copper probe to a clean negative (-) battery terminal (see

Figure 6). The 20' leads may be shortened or extended, if needed. Note: An

improperly installed or corroded battery terminal may generate heat and severe-

ly diminish charging and impede accurate temperature sensing.

2. While observing polarity, connect the battery temperature pins to the positive and

negative terminals as shown on Figure 4.

Note: Battery #1 terminal temperature compensates andactivates alarm. Battery #2 terminal activates the warning alarm only.

Lamp / Alarm Outputs

The MC-624 includes an output terminal for system alarms (dash lamp). This terminal outputs battery negative (0.5-amp max)

when in alarm condition. Refer to Figure 7 for common system conditions that may initiate an alarm.

Small Engine Mode

The MC-624 can be modified for provide a half-power setting by installing a toggle switch between the positive and negative

terminals of the alternator temperature sensor circuit. When activated by closing the switch, the regulator reduces the alterna-

tor output by approximately 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 Output.

V. SHORT DISPLAY

The Model MC-624 provides a wide range of operational, programming and diagnostic data through its 3-digit numeric LED

readout. After an initial start-up period, the numeric LED will cycle through the Short Display, shown in Figure 8 on the fol-

lowing page. The short display includes manufacturer, model, battery type, charging cycle, actual voltage and target voltage.

This display cycles continuously during regulator operation.

Figure 4 -Proper attachment of

optional battery and alternator temp

sensors at the regulator.

Figure 5 - Mounting temperature

sensor mid-case on small case

alternator.

Figure 6 - Mounting temperature

sensor on battery.

Alarm Output Functions

Alarm Output (Dash Lamp)

(-) 0.5 amp - when in alarm mode

• Low battery voltage (030)

• High battery voltage (040)

• High temperature at battery #1 (020)

• High temperature at battery #2 (021)

• High temperature at alternator (022)

Figure 7 - Alarm output functions.

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VI. PRESET BATTERY PROGRAMMING

In addition to its Universal (default) factory program, which can be used safely

with most battery types, the MC-624 features programs for: gel, standard lead

acid, deep-cycle lead acid, AGM (absorbed glass mat), Optima (spiral), as well

as voltage-sensitive (halogen) applications.

The MC-624 is equipped with a magnetic reed switch, embedded in the epoxy

potting, which activates the regulator’s program-

ming. The switch works in two specific actions,

described in the shaded box below:

To set the regulator for your desired battery pro-

gram:

1. ‘ACTIVATE-HOLD’ the switch. The display will

show the “Pro” mode, indicating that the

Program mode has been activated.

2. ‘HOLD’ while the display scrolls, until the

numeric equivalent to your battery type is dis-

played on the LED screen. See Figure 10 to

determine which selectable preset program is

most desirable for your battery technology.

Figure 11 provides detailed information

regarding preset programs.

3. ‘RELEASE’ when the desired value is attained.

4. Once a value has been chosen, the display will return to the “Pro” mode. At this point, you can adjust, up or down, by

repeating Steps 1 through 3 until the numeric display reflects your desired preset program.

If no changes are made, the program you have selected will be locked into permanent memory until modified. The “SAV”

code will be displayed, indicating the program has been locked into memory.

SD Mode 1 - Manufacturer name.

Readout displays “BAL”.

SD Mode 2 - Regulator model.

Readout displays “624”.

SD Mode 4 - Battery type. Readout

displays abbreviated battery type.

SD Mode 5 - Charging stage. Shows

current stage of charging cycle. See

Figure 12 on Page 5.

SD Mode 6 - Battery voltage.

Displays current battery voltage state.

SD Mode 7 - Calculated voltage.

Readout displays voltage target

based on charging stage.

Figure 8 - Short display (SD).

SD Mode 3 - Battery type. Readout

displays program currently in memory.

Figure 9 - Operation of

magnetic reed switch.

Figure 10 - Selectable battery presets.

Universal Factory Program

(UFP). For multiple battery types.

Flooded Deep Cycle (Fdc). For

deep-cell lead acid batteries.

Sealed Gel Cell (GEL). For

sealed gel batteries.

Absorbed Glass Mat (AGL). For

AGM batteries.

Optima (OPS). For Optima spiral

wound batteries.

Flooded Standard (FSB). For

standard lead acid batteries.

Halogen (HAL). For voltage

sensitive applications.

‘ACTIVATE-RELEASE’ Refers to the activation and immediate deactivation of

the switch by lowering a magnetic tool (such as a pocket screwdriver with a

magnetic tip -- see Figure 9) onto the upper corner of the switch, and immedi-

ately deactivating the switch by removing the magnet from the switch. An LED

dot, described in Figure 9 will indicate switch activation.

‘ACTIVATE-HOLD ... 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 PrA Mode is acti-

vated. If you miss your desired program value, release the switch and re-activate, the

cycling direction will automatically change. Any advanced programming values will be

retained within the regulator’s memory until the preset battery programming is reset.

Primary Program Settings PRG-1 PRG-2 PRG-3 PRG-4 PRG-5 PRG-6 PRG-7

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) 28.40 29.20 28.20 28.76 29.20 28.80 28.00

Bulk Time (Minimum) 36 min. 36 min. 36 min. 36 min. 36 min. 36 min. 36 min.

Absorption Voltage 27.80 28.80 27.80 28.36 28.80 28.40 27.60

Absorption Time (Minimum) 36 min. 36 min. 36 min. 36 min. 36 min. 36 min. 36 min.

Float Voltage 27.00 26.70 27.40 26.76 26.80 28.40 27.00

Float Time (Maximum) 6 hr. 6 hr. 6 hr. 6 hr. 6 hr. 6 hr. 6 hr.

High Voltage Alarm 30.40 31.20 30.20 30.76 31.20 30.80 30.00

Low Voltage Alarm 25.60 25.60 25.60 25.60 25.60 25.60 25.60

Max Battery Temperature 125F/52C 125F/52C 125F/52C 125F/52C 125F/52C 125F/52C 125F/52C

Max Alternator Temperature 225F/107C 225F/107C 225F/107C 225F/107C 225F/107C 225F/107C 225F/107C

Equalization (User Prog.) Yes Yes No No No Yes No

Figure 11 - Preset program values. Voltages shown may vary by +/- 3% from values shown.

Indicates ‘ACTIVATE’

VIII. Advanced

Programming

Advanced programming levels can

be accessed when the MC-624 is in

Long Display mode. To access:

1. With regulator in Long Display

mode, ACTIVATE-HOLD until

the “Pro” display code appears.

RELEASE. The “PrA” display

code will appear. (CAUTION: If

the switch is held too long,

the regulator will return to the

preset program adjustment

mode). Once in advanced pro-

gram mode, the display will

cycle through the the individual

advanced programming selec-

tions (see Figure 14).

2. When the desired advanced

program mode is reached,

ACTIVATE-HOLD. The display

will scroll through the available

time or voltage value selections. - 5 -

Figure 13 - Long Display (LD) attributes as displayed on digital numeric readout.

Figure 14 - Advanced Programming (PrA) as displayed on digital numeric readout.

VII. Additional Displays

Charging Stages

The MC-624 utilizes up to 12 individ-

ual stages to ensure proper charg-

ing. Each stage may contain a spe-

cific voltage or time value, or a com-

bination of values which may be

implemented by the regulator’s

microprocessor as it monitors your

battery’s state of charge. These

stages are displayed in both Short

and Long Display modes, and are

described in Figure 12.

Long Display

At any time during the Short

Display’s continuous cycle, addition-

al data for various operations and

diagnostic information can be moni-

tored by accessing the numeric read-

out’s Long Display mode.

To access the Long Display, ‘ACTI-

VATE-RELEASE’ the reed switch

while the Short Display is cycling.

The numeric LED will immediately

return to the “BAL” code and start

cycling through the Long Display.

See Figure 13 for code definitions.

Once the Long Display has cycled

through all of its information modes,

the display will automatically revert

to the Short Display.

LD Mode 1 - Readout displays “BAL”

(Short for Balmar.)

LD Mode 2 - Regulator model.

Readout displays “624”.

LD Mode 3 - Program level. (P)

Displays program currently in memory.

LD Mode 4 - Battery type. Readout

displays abbreviated battery type.See

Figure 10 for descriptions.

LD Mode 5 - Charging stage Displays

the specific stage of the charging

cycle. See Figure 13 for descriptions.

LD Mode 6 - Battery voltage.

Shows current system voltage.

LD Mode 7 - Calculated (Target) volt-

age based on program mode.

LD Mode 8 - Revision number.

Displays software version.

LD Mode 9 - Battery #1 temp.

Followed by the sensor reading

in degrees(Celcius).

LD Mode 10 - Battery #2 temp.

Followed by the sensor reading

in degrees(Celcius).

LD Mode 11 - Factory use only.

LD Mode 12 - Factory use only.

LD Mode 13 - Run time. “Hr ”

code is followed by a numeric

readout in 1/10-hr increments.

LD Mode 14 - Explanatory

mode. May be followed by one or

more diagnostic codes. See

Figure 17 for details.

PrA Mode 1 - Advanced program

mode indicator.

PrA Mode 2 - Start delay “DL”. Adjusts

seconds before ramp up.

PrA Mode 3 - Bulk voltage control. “Bv”

code is followed by volt reading. Adjust up

or down.

PrA Mode 4 - Bulk time control. “Bc”

code is followed by time reading. Adjust

up or down.

PrA Mode 5 - Absorption voltage control.

“Av” code is followed by volt reading.

Adjust up or down.

PrA Mode 6 - Absorption time control.

“Ac” code is followed by time reading.

Adjust up or down.

PrA Mode 7 - Float voltage con-

trol “Fv”. Followed by time read-

ing. Adjust up or down.

PrA Mode 8 - Float time control.

“Fc” code is followed by time

reading. Adjust up or down.

PrA Mode 9 - Amp Manager

control. See details for Amp

Manager on following page.

PrA Mode 10 - Equalization

Voltage control. See details for

Equalization on following page.

PrA Mode 11 - Equalization

Time control. See details for

Equalization on following page.

Stage 1 - Start Delay. Provides a 45-

second delay before load is placed on

engine and belts. Adjust time in PrA*.

Stage 2 - Soft Ramp. One minute volt-

age ramp minimizes belt slippage.

Non-adjustable.

Stage 3 - Bulk. 30-minute set period.

Program determines charging voltage.

Time/voltageadjustable in PrA*.

Stage 4 - Calculated Bulk. Time varies

by state of charge at end of Stage 3.

Adjustable in PrA*.

Stage 5 - Ramp Down. Transition

from Bulk to Absorption stage. Non-

adjustable.

Stage 6 - Absorption. 30-min. set time.

Preset program sets charging voltage.

Time/voltage adjusts in PrA*.

Stage 7 - Calculated Absorption.

Time varies by state of charge at

end of Stage 6. Adjust in PrA*.

Stage 8 - Ramp Down.

Transition from Absorption to

Float stage. Non-adjustable.

Stage 9 - Float. 30-minute time

period. Program sets charging

voltage. Time/volts adjust in PrA*.

Stage 10 - Calculated Float. Time

& voltage based on state of charge

at end of Stage 9.Adjust in PrA*.

Stage 11 - Ramp to Equalize.

Batteries should be at full charge

before initiating eqalization.

Stage 12 - Equalization. Time

and Voltage adjustable in PrA*.

See battery mfg. limits for time

and voltage values. User set.

PrA* - Time and/or voltage adjustments can be made in the Advanced Program mode.

Figure 12 - Charge stage codes as seen in Short and Long displays.

Advanced Programming and Diagnostics

Amp Manager

TheAmp Manager function enables you to reduce the alternator output by controlling the volt-

age at the field wire. This feature can be used as a method to minimize alternator overheat-

ing in warmer climates, as well as minimizing difficulties with chronic belt slippage. To adjust

Amp Manager values:

1. ‘ACTIVATE-RELEASE’ when display cycles to “AP” (PrA Mode 09). “AP” will be fol-

lowed by “OFF” code.

2. ‘ACTIVATE-HOLD’ “OFF” display cycles to “249”. The value “249” represents full field

output. The numeric value on the display will decrease until you RELEASE.

Note: The value “200” represents approximately 75% field output, “150” represents approx-

imately 50% field output, and “75” represents approximately 25% field output.

Equalization Mode

Equalization mode allows owners of some battery types to increase charging voltage for the purpose of minimizing battery sul-

fation. (Equalization is only suggested for batteries noted as “equalization friendly” in Figure 11 on Page 4). Consult

your battery manufacturer to determine what equalization time and voltage is best for your specific battery. Equalization must

be initiated through the advanced programming mode. It is NOT a standard mode of opera-

tion. This feature should ONLY be used periodically on batteries requiring equalization. Once

equalization voltageAND time values are chosen and saved into the regulator’s programming,

the equalization process will start immediately. Once equalization has occurred, the regulator

will revert to its preset program status. When equalization is once again warranted, the user

will need to re-activate the equalization mode. Equalization voltage is limited to 31.2 volts.

To adjust equalization voltage (PrA Mode 10):

1. ‘ACTIVATE-RELEASE’ “PrA” display cycles to “Ev” followed by “OFF” code.

2. ‘ACTIVATE-HOLD’. “OFF” display cycles to numeric voltage values. When the manu-

facturer-recommended voltage is reached, RELEASE.

To adjust equalization time (PrA Mode 11):

1. ‘ACTIVATE-RELEASE’ “PrA”. Display cycles to “Ec” followed by “OFF” code.

2. ‘ACTIVATE-HOLD’. “OFF” display cycles to numeric equalization time values. When the

manufacturer-recommended time value is reached, ‘RELEASE’.

Explanatory / Advisory Codes

The codes in the final mode of the Long Display (LD Mode 14) provide a wide range of advisories regarding regular operations

and possible technical difficulties. The descriptions for these codes can be found in Figure 17. For additional technical infor-

mation regarding Explanatory and Advisory codes, see our Technical Support pages at the Balmar website (http://www.bal-

mar.net). To reset advisory/diagnostic codes, access the Advanced Programming mode as described at the beginning

of Section VIII. Codes will automatically reset.

- 6 -

Figure 17 - Advisory/diagnostic codes as displayed in LD Mode 14 on the digital numeric readout.

CODE 001 - Factory use only.

CODE 002 - Factory use only.

CODE 010 - Wire short at battery #1 tempera-

ture sensing terminal.

CODE 011 - Factory use only.

CODE 012 - Wire short at battery #2 tempera-

ture sensing terminal.

CODE 013 - Factory use only.

CODE 014 - Wire short at alternator temperature

sensor terminal.

CODE 015 - Sensor wire not found at alternator

temperature sensor terminal.

CODE 020 -Factory use only.

CODE 021 -Battery #2 exceeding recommended

temperature limits.

CODE 022 -Factory use only.

CODE 024 - Factory use only.

CODE 030 -Voltage too low at battery.

CODE 031 - Factory use only.

CODE 032 - Factory use only.

CODE 040 -Voltage too high at battery.

CODE 041 - Factory use only.

CODE 042 - Factory use only.

CODE 050 - Open field.

CODE 051* -Small Engine Mode activated.

CODE 052* -Amp manager is in operation.

Underlined codes represent those pertaining to

Alarm Output (dash lamp) operation.

Codes highlighted by an asterisk (*) pertain to

Aux. #1 advisory output.

Figure 16 - Equalization

Voltage mode is activated.

3. RELEASE when desired values are reached. Inversely, the values can be decreased, if desired. ACTIVATE-HOLD while

values decrease. RELEASE when desired value is attained.

4. The PrA mode will cycle 3 times. Any changes made during those cycles will be saved.

Figure 15 - Indicates Amp

Manager Mode.

NOTES:

IX. SYSTEM TROUBLESHOOTING

Determining the causes of failures in an electrical system is a “step by step” process. We recommend that you inspect and clean all system

electrical connections before you begin your search to determine if the failure can be attributed to one of the two main components of your

charging system: the alternator, and/or the voltage regulator.

Most charging system problems will be corrected by performing the following steps.

1. Remove and clean all charging system electrical connections from the alternator through the batteries (this includes the ground side).

Also, check the voltage regulator’s harness for resistance. Wires and terminals can and will become corroded and need to be cleaned

or replaced.

2. Charge all batteries to their proper fully charged state and determine if they are serviceable. If your batteries are flooded-type, use your

hydrometer to determine their condition.

3. Check and tighten alternator belt. If the belt shows signs of wear or damage, now is an ideal time for replacement. Always replace

existing belts with the finest quality replacements available.

After determining that your batteries and wiring are in suitable condition, use the following tests to determine if charging problems are a result

of a faulty alternator or regulator. The following tests provide an opportunity to isolate the alternator, regulator and wiring harness in order to

determine which component may be malfunctioning. In order to preform these tests, you will need an independent multimeter (preferably a

digital type). In an emergency, a 24V light bulb can be used to help determine if power or working grounds exist. An amp meter and a bat-

tery hydrometer with a thermometer are also helpful diagnostic tools.

Alternator /Regulator Field Tests

Test A - The alternator and regulator can be tested for function by determining if a magnetic field exists at the alternator’s pulley shaft or rear

bearing. To test:

1. With the ignition in the OFF position, place the head of a steel screwdriver near the nut on the pulley shaft or near the rear bearing of

the alternator. There should be no evidence of a magnetic field pulling the screwdriver toward the alternator.

2. Engage the ignition, without starting the engine, to activate the voltage regulator. If an oil pressure switch is used, a jumper across the

switch will activate the regulator.

3. After allowing time for the regulator’s start-up 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 evidence of a magnetic field pulling the screwdriver toward the alternator. If a magnet-

ic field is present, the voltage regulator, alternator brushes and rotor are likely to be working prop-

erly. If the system is not charging, remove the alternator and have it inspected by a qualified alter-

nator shop.

Test B - If there is little or no magnetic pull at the pulley shaft or at the rear bearing, initiate the follow-

ing test:

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

2. Insert the end of a short length of electrical wire to the RED connector slot of the regulator har-

ness and the other end of the wire to the BLUE connector slot. (See Figure 18.) This bypasses

the regulator and tests the alternator and the harness.

3. Using your steel screwdriver, inspect for a magnetic field as described above.

4. With your voltmeter, check for voltage on the blue wire at the alternator. If voltage does not exist,

the harness may be at fault. If voltage does exist at the harness, but charging is not occurring,

the alternator is likely to be malfunctioning.

If a magnetic field is present. Both harness and alternator brushes and rotor appear to be working prop-

erly. If no magnetic field is present, proceed with the next test.

Test C - Testing the actual output of the alternator is known as “Full Field Testing”. This can be accomplished by jumping a positive 24VDC

current to the field terminal at the rear of the alternator. 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 test and could damage sensitive electronics. DO NOT let the engine run any longer than neces-

sary to detect charging.

To test the alternator:

1. Clip a jumper wire to the positive post of the alternator, or on the battery side of the isolator, if an isolator is in use. Use a SHIELDED

alligator clip for post attachment. Unintentional contact between the alligator clip and the alternator case could result in damage to

your electrical system.

2. Disconnect the field/stator plug from the rear of the alternator and attach the other end of the jumper wire to the alternator’s Field ter-

minal (F). Attach a female spade connector to the field end of the wire for a solid connection. CAUTION: Do not allow the wire to con-

tact the case while it is attached to the positive post. The case is grounded and severe damage could occur.

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

should be present.

4. The motor should be run long enough to determine that charging voltage is present. Unregulated voltage can rise quickly. Do not allow

extended unregulated charging to occur without carefully monitoring voltage levels.

If the alternator fails to generate voltage during field testing, a malfunction of the alternator is likely. Contact your local alternator repair shop

or Balmar’s technical service staff for recommendations.

Voltage Regulator Test

When you have inspected and repaired any wires and connections, inspected belts and replace as needed, and after you have determined

- 7 -

Figure 18 - Jumping power wire

to field.

that your batteries are properly charged, set your voltmeter to 24V and connect the

voltmeter’s negative lead to the BLACK ground wire at the regulator. Normally, con-

nection is accomplished by inserting the negative lead alongside the ground wire in

the regulator harness plug (see Figure 19) and the positive lead alongside the wire

referred to in each specific test. With the voltmeter securely connected to the regula-

tor’s ground, test for voltage at the points listed below.

1. With the ignition in the OFF position and your voltmeter’s ground wire con-

nected to the regulator’s ground, check for voltage on the RED (sensing),

BLUE (field) and BROWN (ignition) wires in the regulator plug by inserting the

positive lead of the voltmeter alongside each wire in the regulator harness

plug. The voltmeter should read:

Red Wire Brown Wire Blue Wire

Expected Reading 24 V * 0 V 0 V

Your Reading

2. With the ignition in the ON position (engine not running) and your voltmeter’s ground wire connected to the regulator’s ground, check

for voltage on the RED (sensing), BLUE (field) and BROWN (ignition) wires in the regulator plug. The voltmeter should read:

Red Wire Brown Wire Blue Wire

Expected Reading 24 V* 24 V >24 V

Your Reading

3. With the ignition in the ON position (with engine running at 1,400 rpm fast idle) and your voltmeter’s ground wire connected to the reg-

ulator’s BLACK wire, check for voltage on the RED (sensing), BLUE (field) and BROWN (ignition) wires in the regulator plug. The volt-

meter should read: Red Wire Brown Wire Blue Wire

Expected Reading 24 - 28V** 24 V >25 V

Your Reading

* 23-24.5 VDC battery voltage at rest (no charging occurring). If your batteries are isolated and your RED (sensing) wire shows voltages other than those shown above, make sure

that the wire is connected on the “battery” side of the isolator. The RED wire must “see” the battery directly.

** 27 - 28 VDC battery voltage when charging.

If your readings differ substantially from the “Expected Readings” listed in the charts above, the regulator may be malfunctioning, or there

may be a continuity problem. Contact our technical support staff at (360) 435-6100. Keep your recorded readings in the spaces provided

below the “Expected Readings” so you can share them with the technical support person. If your readings match those listed in the charts,

your regulator should be working correctly. Continue with tests below to determine if your alternator may be the source of charging difficul-

ties.If the preceding tests do not prove the existence of a failure within the regulator or alternator, we recommend you contact a licensed

marine electrician who can test your system for wiring and circuit damage or other system failures that could be responsible for charging dif-

ficulties. If you determine that repair service is necessary for either your alternator or regulator, please gather the following information before

contacting our service technicians.

1. Model of alternator.

2. Model of voltage regulator.

3. Voltage readings on red, brown and blue wire at regulator with engine off, key on.

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

- 8 -

XII. LIMITED PRODUCT WARRANTY

BALMAR warrants to the original consumer/purchaser 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 ship-

ping 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 prod-

ucts 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, 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, 19009 61st

Ave. NE,Arlington, WA98223. 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.