Balmar Max Charge MC-612 Setup guide

- 1 -
I. INTRODUCTION
The microprocessor-controlled Max
Charge MC-612 is the most advanced
regulator available. Designed to continu-
ally monitor battery voltage and auto-
matically optimize charging the MC-612
uses up to 12 time and voltage increments
to ensure your batteries receive a full charge quickly and
safely.
The MC-612 lets you choose from a variety of selectable
preset programs to best suit your charging needs. IIttss
UUnniivveerrssaall FFaaccttoorryy PPrrooggrraamm aalllloowwss yyoouu ttoo ccoonnnneecctt tthhee MMCC-661122
ttoo yyoouurr aalltteerrnnaattoorr rriigghhtt oouutt ooff tthhee bbooxx..Six additional preset pro-
grams support 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 regu-
lator adjustment. Should your charging system require individualized adjustment the MC-612 provides additional user-defined
programming options.
When used with optional alternator and battery temperature sensors the MC-612 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 con-
ditions.
II. SAFETY CONSIDERATIONS
Before installing your MC-612 marine regulator please take a moment to consider
these guidelines for safe regulator installation. Failure to work safely could result in per-
sonal 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 regulator 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-612 regulator.
If you are unfamiliar with marine electrical systems consult with a licensed marine
electrician.
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 qual-
ified marine electrical technician.
19009 61st Ave. NE, Arlington, WA 98223 PHONE: [phone]
FAX: [phone] E-MAIL: [e-mail] WEB: WWW.BALMAR.NET
Max Charge MC-612 Regulator
In tallation and Operator’ Manual
III. BASIC INSTALLATION
The MC-612 can be purchased with or without a standard 54" harness. When
installing without the harness or if the wiring needs to be extended beyond the length
of the harness marine grade 12AWG (American Wire Gauge) wire should be used.
©Copyright 2001 Ballard Commercial Industries, Inc. Revised 3/15/2002
TABLE OF CONTENTS
I. Introduction
II. Safety Considerations
III. Basic Installation
IV. Alarm and Sensor Installation
V. Short Display
VI. Preset Battery Programming
VII. Long Display
VIII. Advanced Programming
Amp Manager
Equalization
System Diagnostics
IX. Troubleshooting
Warranty
Sample System Wiring
Single Output Alternator
Dual Output Alternator
Express Installation Instructions

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. 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 bat-
tery side of the isolator. On a 12V system this wire can carry
8 amps and must be protected by a 10-amp fuse. A fuse is
included with the wiring harness.
3. The POSITIVE battery sense wire as shown in the illustration
at right monitors battery voltage. The positive and negative
sense wires MUST be connected for the regulator to work.
The positive sense wire should be connected 1) at the bat-
tery if only one battery bank is used; 2) at the "common"
terminal of the battery selector switch for multi-bank charg-
ing; or 3) on the isolator terminal for the largest battery bank
(if isolator is used). This wire is user supplied and should be
14 -gauge (minimum). Spade and ring terminals and a 1-A
mini fuse pigtail are provided. Refer to regulator side label or Figure 3
below for terminal locations. Caution: Sense wires MUST always see the bat-
tery being charged. Be sure to observe polarity when connecting. When con-
nected the Positive Battery Sense draws approximately .53mA .
4. The BROWN (ignition) wire activates the regulator when +12VDC is applied
to the system. Attach the BROWN wire to a switched +12VDC source. The
auxiliary side of the ignition switch or an independent (ungrounded) oil
pressure switch are both acceptable connection points. A toggle switch may
be added to this circuit to shut down the alternator load in cases where
maximum propulsion is needed.
5. Attach the Ford-type harness plug to the regulator (see illustration). The sec-
ond BLACK (ground) wire in the harness attaches to the Negative Battery
Sense Terminal. Both BLACK wires attach to preferred ground terminal on
the alternator. A (user supplied) ground strap between the alternator and
the preferred ground at the engine is also strongly recommended.
6. Plug duplex connector with BLUE (field) and White (stator) wires into rear of
alternator.
7. If you are using an electrical tachometer that is being driven off of your alternator's stator pulse plug the white stator wire into the ter-
minal 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 regulator's 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 creeping up
when your batteries are fully charged. This occurs as a result of the regulator's 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 increasing the load on the batteries ie.
turning on a few cabin lights or cabin fans until the batteries are allowed to accept charging voltage.
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FFiigguurree 11- Regulator wiring attachment.
FFiigguurree 22- Wire size chart. Represents 3% voltage drop.
Lengths should be measured in round trip.
FFiigguurree 33- Regulator terminal la out.
Length 10 Ft. 15 Ft. 20 Ft. 25 Ft. 50 Ft 75 Ft. 100 Ft.
Amps
25 1088 642 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 regulator to sense when the alternator tem-
perature exceeds safe working limits. The MC-612 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-
612 (See Figure 4). Observe proper polarity at the terminals.
2. Attach the heavy lug terminal to a location described below on your alternator. Flat washers are
included with the temperature sensors to ensure solid mounting connections. The following are
typical installation locations:
MID CASE MOUNT - Small Case Alternator - Remove (1) of (4) 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 maintain alternator
temperature. Optional temperature sensors are not a
guarantee of protection against damage from over-
heat 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-612 will automatically compensate for
variation above and below normal ambient tempera-
tures. The MC-612 is equipped with dual battery sen-
sors to enable sensing at two separate batteries. To
ensure proper operation be sure the battery terminals
are completely clean and free of corrosion prior to
installation. To install the Battery Temperature Sensor:
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 severely diminish charging
and impede accurate temperature sensing.
2. While observing polarity connect the battery temperature pins to the positive and nega-
tive terminals as shown on Figure 4.
Note: Battery #1 terminal is capable of temperature compensation and activating
warning alarm. Battery #2 terminal activates the warning alarm only. The upper volt-
age limit for battery compensation is 14.8 volts. If higher voltage limits are desired
adjust voltage levels in the Compensation Limit (CL) mode of the advanced program-
ming adjustments.
Lamp / Alarm Outputs
The MC-612 includes two output terminals one for system alarms (dash lamp) and and another for advisory information (Aux.
#1). These terminals output battery negative (0.5-amp max) when in alarm condition. Refer to Figure 7 for common system con-
ditions that may initiate an alarm. When in the alarm mode the 3-digit numeric display will indicate the exact cause for the alarm.
Specific advisory codes are shown in Figure 17 on Page 6.
Small Engine Mode
The MC-612 can be modified for provide a half-power setting by installing a toggle switch between the positive and negative ter-
minals of the alternator temperature sensor circuit. When activated by closing the switch the regulator reduces the alternator
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-612 provides a wide range of operational programming and diagnostic data through its 3-digit numeric LED read-
out. After an initial start-up period the numeric LED will cycle through the Short Display shown in Figure 8 on the following page.
The short display includes manufacturer model battery type charging cycle actual voltage and target voltage. This display cycles
continuously during regulator operation.
FFiigguurree 44 - Proper attachment of
optional batter and alternator
temp sensors at the regulator.
FFiigguurree 55- Mounting temperature
sensor mid-case on small case alter-
nator.
FFiigguurree 66- Mounting temperature sen-
sor on batter .
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)
Au . #1 (Advisory) Output
(-) 0.5 amp - when in alarm mode
• Alt. output at full capacity
• Small engine option activated (0 1)
• Equalization mode activated
FFiigguurree 77- 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-612 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-612 is equipped with a magnetic reed switch
embedded in the epoxy potting which activates the
regulator’s programming. The switch works in two
specific actions described in the shaded box below:
To set the regulator for your desired battery program:
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 displayed on the
LED screen. See Figure 10 to determine which
selectable preset program is most desirable for your
battery technology. Figure 11 provides detailed infor-
mation 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 “612”.
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.
FFiigguurree 88- Short displa (SD).
SD Mode 3 - Battery type. Readout
displays program currently in memory.
FFiigguurree 99- Operation of mag-
netic reed switch.
FFiigguurree 1100- Selectable batter 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.
1
2
3
4
5
6
7
‘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 immediately deacti-
vating 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 activat-
ed. 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 with-
in 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) 14.10 14.60 14.10 14.38 14.60 14.40 14.00
Bulk Time (Minimum) 36 min. 36 min. 36 min. 36 min. 36 min. 36 min. 36 min.
Absorption Voltage 13.90 14.40 13.90 14.18 14.40 14.20 13.80
Absorption Time (Minimum) 36 min. 36 min. 36 min. 36 min. 36 min. 36 min. 36 min.
Float Voltage 13.42 13.35 13.70 13.38 13.40 13.40 13.50
Float Time (Maximum) 6 hr. 6 hr. 6 hr. 6 hr. 6 hr. 6 hr. 6 hr.
High Voltage Alarm 15.20 15.60 15.10 15.38 15.60 15.40 15.00
Low Voltage Alarm 12.80 12.80 12.80 12.80 12.80 12.80 12.80
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
FFiigguurree 1111- Preset program values. Voltages shown ma var b +/- 3% from values shown.
Indicates ‘ACTIVATE’

VIII. ADVANCED PROGRAMMING
Advanced programming levels can be
accessed in Long Display mode. To
access:
1. With regulator in Long Display mode
AACCTTIIVVAATTEE-HHOOLLDDuntil the “Pro” display
code appears. RREELLEEAASSEE. 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 program mode the
display will cycle through the various
advanced programming modes (see
Figure 14).
2. When the desired advanced program
mode is reached AACCTTIIVVAATTEE-HHOOLLDD.
The display will scroll through the
available time or voltage value selec-
tions.
3. RREELLEEAASSEEwhen desired values are
reached. Inversely the values can be
decreased if desired. AACCTTIIVVAATTEE-HHOOLLDD
while values decrease. RREELLEEAASSEE
when desired value is attained.
4. The PrA mode will cycle 3 times. Any
changes made during those cycles
will be saved.
- 5 -
FFiigguurree 1133- Long Displa (LD) attributes as displa ed on digital numeric readout.
FFiigguurree 1144- Advanced Programming (PrA) as displa ed on digital numeric readout.
VII. ADDITIONAL DISPLAYS
Charging Stages
The MC-612 uses up to 12 individual stages
to ensure proper charging. Each stage may
contain a specific voltage or time value or a
combination of values. These stages are dis-
played in both Short and Long Display
modes and are described in Figure 12.
Long Display
To access the Long Display ‘ACTIVATE-
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 “612”.
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) voltage
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 - Tach reading.
Activate and adjust for alternator
pole type in advanced programming.
LD Mode 15 - Explanatory mode.
May be followed by one or more
diagnostic codes. See Figure 17.
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 read-
ing. Adjust up or down.
PrA Mode 4 - Bulk time control.
“Bc” code is followed by time read-
ing. 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 con-
trol. “Ac” code is followed by time
reading. Adjust up or down.
PrA Mode 7 - Float voltage control
“Fv”. Followed by time reading.
Adjust up or down.
PrA Mode 8 - Float time control.
“Fc” code is followed by time read-
ing. Adjust up or down.
PrA Mode 9 - Amp Manager con-
trol. 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.
PrA Mode 12 - Alternator Constant.
Emulates tachometer reading. See
following page for adjustment.
PrA Mode 13 - Compensation
Limit. Limits max. temperature com-
pensation. See 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 volt-
age. 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 volt-
age values. User set.
PrA* - Time and/or voltage adjustments can be made in the Advanced Program mode.
FFiigguurree 1122- Charge stage codes as seen in Long Displa .
Advanced Programming and Diagno tic

Amp Manager (AP)
The Amp 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 overheating
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 followed 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.
NNoottee::The value “200” represents approximately 75% field output “150” represents approx-
imately 50% field output and “75” represents approximately 25% field output.
Equalization Mode (EQ)
Allows increase in charging voltage to minimize battery sulfation. ((EEqquuaalliizzaattiioonn iiss OONNLLYY ssuugg-
ggeesstteedd ffoorr bbaatttteerriieess nnootteedd aass ““eeqquuaalliizzaattiioonn ffrriieennddllyy”” iinn FFiigguurree 1111 oonn PPaaggee 44)). Consult your bat-
tery manufacturer for equalization time and voltage recommendations. Equalization must be
initiated through the advanced programming. It is NOT a standard mode of operation. Once
equalization voltage and time values are saved into the regulator’s programming the equal-
ization process will start immediately. Once equalization has occurred the regulator will revert
to its preset program status. The user will need to re-activate equalization mode for subse-
quent anti-sulfation conditioning. For system safety equalization voltage is limited to 15.8
volts.
TToo aaddjjuusstt eeqquuaalliizzaattiioonn vvoollttaaggee ((PPrrAA MMooddee 1100))::
1. ‘ACTIVATE-RELEASE’ “PrA” display cycles to “Ev” followed by “OFF” code.
2. ‘ACTIVATE-HOLD’. “OFF” display cycles to numeric voltage values. When the manufacturer-recom-
mended voltage is reached RELEASE.
TToo aaddjjuusstt eeqquuaalliizzaattiioonn ttiimmee ((PPrrAA MMooddee 1111))::
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 manufactur-
er-recommended time value is reached ‘RELEASE’.
Alternator Constant Mode (ALC)
Emulates tachometer readings on regulator display. Must be activated in Advanced
Programming. To determine proper calibration value divide 384 by the number of poles in your
alternator. (A 14-pole alternator has a calibration value of 27.)
TToo eennaabbllee AALLCC ((PPrrAA MMooddee 1122))::
1. ‘ACTIVATE-RELEASE’ “PrA” display cycles to “ALC” followed by “OFF” code.
2. ‘ACTIVATE-HOLD’. “OFF” display cycles to numeric calibration values. When the proper calibration
value is reached RELEASE.
Compensation Limit (CL)
When equipped with optional Battery Temperature Sensor the MC-612 will automatically adjust
charging voltage to compensate for ambient battery temperature. In default mode the regula-
tor is limited to maximum compensated voltage of 14.8 volts (to minimize the likelihood of over-
voltage shutdown by inverters and combiners). Compensation Limit allows the user to advance
or decrease maximum compensated voltage to suit specific charging system needs.
TToo eennaabbllee CCLL ((PPrrAA MMooddee 1133))::
1. ‘ACTIVATE-RELEASE’ “PrA” display cycles to “CL”.
2. ‘ACTIVATE-HOLD’. Default voltage value of 14.8 cycles to increasing voltage values. To decrease
voltage values RELEASE wait for the voltage value to disappear. Re-activate and hold. When the
proper voltage value is reached RELEASE.
E planatory / Advisory Codes
Descriptions for these codes can be found in Figure 17. For additional technical information see
our Technical Support pages at the Balmar website (http://www.balmar.net). To reset adviso-
ry/diagnostic codes access the Advanced Programming mode as described at the beginning of
Section VIII. No changes need to be made to programming once the Advanced Programming
mode is accessed. AP mode will cycle three times and return to normal mode. Codes will auto-
matically reset when AP mode is complete.
- 6 -
FFiigguurree 1177- Advisor /diagnostic
codes.
CODE 001 - Factory use only.
CODE 002 - Factory use only.
CODE 010 - Wire short at battery #1 tem-
perature sensing terminal.
CODE 011 - Sensor wire not found at bat-
tery #1 temperature sensing
terminal.
CODE 012 - Wire short at battery #2 tem-
perature sensing terminal.
CODE 013 - Sensor wire not found at bat-
tery #2 temperature sensing
terminal.
CODE 014 - Wire short at alternator tem-
perature sensor terminal.
CODE 015 - Sensor wire not found at alter-
nator temperature sensor ter-
minal.
CODE 020 -Battery #1 exceeding recom-
mended temperature limits.
CODE 021 -Battery #2 exceeding recom-
mended temperature limits.
CODE 022 -Alternator exceeding recom-
mended temperature limits.
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.
FFiigguurree 1166 - Equalization Voltage
mode is activated.
FFiigguurree 1155- Indicates Amp
Manager Mode.

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.
MMoosstt cchhaarrggiinngg ssyysstteemm pprroobblleemmss wwiillll bbee ccoorrrreecctteedd bbyy ppeerrffoorrmmiinngg tthhee ffoolllloowwiinngg sstteeppss..
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 exist-
ing 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 12V light bulb 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.
Alternator /Regulator Field Tests
TTeesstt AA- 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 screwdriv-
er toward the alternator. If a magnetic field is present the voltage regulator alternator brushes
and rotor are likely to be working properly. If the system is not charging remove the alternator
and have it inspected by a qualified alternator shop.
TTeesstt BB- 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 properly. If no magnetic field is present pro-
ceed with the next test.
TTeesstt CC- 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 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 necessary to detect charg-
ing.
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 alli-
gator 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 contact
the case while it is attached to the positive post. The case is grounded and severe damage could occur.
3. The regulator is now bypassed. When the ignition is engaged and the motor is started the voltage should rise and charging 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.
- 7 -
R
Bl
FFiigguurree 1188- Jumping power wire to
field.

VVoollttaaggee RReegguullaattoorr TTeesstt
When you have inspected and repaired any wires and connections inspected belts and
replace as needed and after you have determined that your batteries are properly charged
set your voltmeter to 12V and connect the voltmeter’s negative lead to the BLACK ground wire
at the regulator. Normally connection is accomplished by inserting the negative lead along-
side the ground wire in the regulator harness plug (see Figure 19) and the positive lead along-
side the wire referred to in each specific test. With the voltmeter securely connected to the
regulator’s ground test for voltage at the points listed below.
1. With the ignition in the OFF position 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 by inserting the positive lead of the voltmeter
alongside each wire in the regulator harness plug. The voltmeter should read:
RReedd WWiirreeBBrroowwnn WWiirreeBBlluuee WWiirree
EExxppeecctteedd RReeaaddiinngg1122 VV **00 VV00 VV
YYoouurr RReeaaddiinngg
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:
RReedd WWiirreeBBrroowwnn WWiirreeBBlluuee WWiirree
EExxppeecctteedd RReeaaddiinngg1122 VV** 1122 VV77 - 1122 VV
YYoouurr RReeaaddiinngg
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 voltmeter
should read:
RReedd WWiirreeBBrroowwnn WWiirreeBBlluuee WWiirree
EExxppeecctteedd RReeaaddiinngg1122 - 1144VV****1122 VV44 - 1122 VV
YYoouurr RReeaaddiinngg
* 11.5 - 12.8 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.
** 13.5 - 14.5 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 [phone]. 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 regula-
tor should be working correctly. Continue with tests below to determine if your alternator may be the source of charging difficulties.If the pre-
ceding 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 difficulties. If you deter-
mine that repair service is necessary for either your alternator or regulator please gather the following information before contacting our serv-
ice 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 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 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 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: [phone], Fax: [phone]
E-mail: [e-mail], Web: www.balmar.net
Red/Black
Brown/Black
Blue/Black
FFiigguurree 1199- Inserting voltmeter probes.

- 9 -
Sugge ted Wiring Option for Single Output Alternator

- 10 -
Sugge ted Wiring Option for Dual Output Alternator

- 11 -
Max Charge MC-612
Quick In tallation In truction
IMPORTANT
The following information is essential to the proper operation of your Ma Charge regulator. Do not install or oper-
ate before reviewing the following:
11..PPoossiittiivvee BBaatttteerryy SSeennssee WWiirree- User supplied -- not in harness. This wire must be connected to the regulator and to a source
of positive battery voltage (see #3 on reverse for mounting location) to provide proper regulator operation. The regulator
WILL NOT WORK if the Positive Battery Sense Wire is not connected to the regulator and is not sensing battery voltage.
The Positive Battery Sense Wire must be fused. A 1/8-amp fuse is included with the regulator and harness kit.
22..GGrroouunnddiinngg- The Model MC-612 must be properly grounded to regulate accurately. The two ground wires located in the har-
ness must be securely attached to their terminals and the alternator’s preferred ground to ensure proper grounding. A
grounding strap between the alternator’s preferred ground and the preferred ground at the engine is strongly recommend-
ed.
33..VVoollttaaggee RReeaaddiinnggss- MC-612 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 near-constant changes in the regula-
tor’s Battery Voltage display. These voltage changes reflect the regulator’s ability to make precise corrections to optimize
charging efficiency.
55..EElleeccttrriiccaall TTaacchhoommeetteerrss- Many OEM 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 alternator's 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 regulator's Stator connection.
When using the alternator and regulator to drive your tachometer there is a possibility that you will see system voltage
creeping up when your batteries are fully charged. This occurs as a result of the regulator's effort to provide a "blip" of volt-
age to the alternator to keep the tachometer feed activated. This voltage creep can usually be reduced or eliminated by
increasing the load on the batteries ie. turning on a few cabin lights or cabin fans until the batteries are allowed to
accept charging voltage.
44..DDuuaall-OOuuttppuutt OOppeerraattiioonn- When using the MC-612 with a dual-output alternator it is essential to ensure that the regulator
senses the largest battery bank. The positive Battery sense wire must be attached on the alternator output terminal con-
nected to the larger battery bank. If your system includes a large house battery and a smaller starting battery there is the
possibility that the smaller battery may see excess surface voltage during charging. Ensure that your smaller battery is
inspected regularly for electrolyte levels. If optional Battery Temperature Sensors are used we recommend attaching the
#1 Battery Temperature Sensor to the smaller bank. This ensures that the alternator output will be reduced if the starting
battery temperature exceeds safe operating temperatures.
55..AAlltteerrnnaattoorr && BBaatttteerryy TTeemmppeerraattuurree SSeennssoorrss ((ooppttiioonnaall))- The optional Alternator Temperature Sensor monitors for over-tem-
perature conditions at the alternator. If ambient temperatures outside of safe limits are detected the regulator 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 can
compensate for both over-temperature conditions and for operation in conditions where ambient battery temperatures are
below 26°(C) by varying field voltage. It is not unusual to see charging voltage rise safely above normal levels when bat-
tery temperatures are below 26°(C).
66..MMaaggnneettiicc RReeeedd SSwwiittcchh- 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 switch’s “sweet spot.” If you have difficul-
ty adjusting program modes be sure to check for the dot at the top of the LED to ensure that you are activating the switch.

The MC-612 can be installed with very little difficulty if installation instructions are followed carefully. If you are unaccustomed
to marine electrical installations we recommend a licensed marine electrician. To install the MC-612:
1. Mount the regulator in a dry well-ventilated location well away from hoses and exhaust manifolds which may cause dam-
age to the regulator or wiring. Avoid areas of heat and/or high vibration.
2. The RED wire (in the harness) powers the regulator. Attach at the positive output terminal at the back of the alternator. If an
isolator is used this wire must be located on the battery side of the isolator. On a 12V system this wire can carry 8 amps
and must be protected by a 10-amp fuse. A fuse is
included with the wiring harness.
3. The POSITIVE battery sense wire as shown in the illus-
tration at right monitors battery voltage. The positive
sense wire should be connected 1) at the battery if only
one battery is being used; 2) at the "common" terminal
of the battery selector switch for multi-bank charging; or
3) on the isolator terminal for the largest battery bank
(if isolator is used). This wire is user supplied and
should be 16-gauge. Spade and ring terminals and a 1-
A inline fuse are provided. The positive and negative
sense wires MUST be connected for the regulator to
work. Refer to regulator side label for terminal locations.
Caution: Sense wires MUST always see the battery
being charged. Be sure to observe polarity when con-
necting.
4. The BROWN (ignition) wire activates the regulator when
+12VDC is applied to the system. Attach the BROWN
wire to a switched +12VDC source. The auxiliary side of
the ignition switch or an independent (ungrounded) oil pressure switch are both acceptable connection points. A toggle
switch may be added to this circuit to shut down the alternator load in cases where maximum propulsion is needed.
5. Attach the Ford-type harness plug to the regulator (see illustration). The second BLACK (ground) wire in the harness attach-
es to the Negative Battery Sense Terminal. Both BLACK wires attach to preferred ground terminal on the alternator.
6. Plug duplex plug with BLUE (field) and White (stator) wires into rear of alternator.
7. Plug the other end of the WHITE wire into the Stator Terminal on the regulator
(see side label for locations of these and other terminals). Tach Terminal on
the regulator provides pulse for electric tachometer if desired.
The MC-612 is factory preset for use with most battery types. For optimal charging
we recommend choosing one of the six battery-specific selectable programs dis-
cussed on Page 4 of the installation manual. Program choices are: 1) Universal
Factory Program 2) Flooded Deep-Cycle 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 -
Max Charge MC-612 Quick In tallation In truction