Balmar 96 Series Page 24 Installation And Operation Manual Download

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Balmar Knows How To

Charge Your Batteries

Balmar LLC

15201 39th Avenue NE

Marysville, WA 98271

USA

+1 (360) 435-6100

www.balmar.net

CDI Electronics LLC

353 James Record Road SW

Huntsville, AL 35824

USA

+1 (256) 772-3829

www.cdielectronics.com

CDI Electronics designs and manufactures ignition components for

outboard motors and diagnostic software for most Marine Engines. CDI

enjoys relationships with 70 distribution partners around the world. To

Find a CDI distribution partner, visit

www.cdielectronics.com.

Both Balmar and CDI Products are manufactured in our ISO

9000-Certified Factory in Huntsville, Alabama.

Please read carefully. All policies, procedures and instructions are subject

to change. This guide was prepared to provide information and does not

constitute a contract. Balmar reserves the right, without prior notice, to

change, delete, supplement, or otherwise amend at any time the information

and policies contained in this guide.

For the most recent information about Balmar’s products, policies and

instructions please visit,

www.balmar.net.

SUP-0276

Summary of Contents for 96 Series

Page 1: ...become entangled in your motor or other machinery prior to installing regulator and alternator 3 Wear ANSI approved safety eye wear and protective gear 4 DO NOT attempt to modify the regulator or alternator Modifications could result in damage to your charging system and will void your warranty 5 DO NOT attempt installation if you are tired or fatigued 6 Ensure that the engine has cooled before in...

Page 2: ...s a rule of thumb the alternator should be rated at 25 40 of your house battery capacity depending on the battery chemistry 2 Ensure that the belt or belts driving the alternator are capable of handling the alternator s horsepower load 3 Only use the MC 620 regulator with 96 Series alternators and visa versa 4 96 Series alternators are NOT isolated ground they are case ground but provide an auxili...

Page 3: ...inyurl com r8comkd ALTERNATOR OUTPUT TO BATTERY CAPACITY RATIO In order to achieve optimal performance from your charging system it is essential to determine the capacity your charging system is capable of supporting In general the size rating of the alternator should mirror the acceptance rate of the batteries being charged Differing battery technologies will vary in terms of their acceptance rat...

Page 4: ...s stud provides a direct connection to the negative rectifier plate and can be used for best performance with a properly sized negative cable to the battery 3 External Field Wire BLUE Connects to MC 620 voltage regulator via wiring harness 4 Stator Output Wire WHITE Provides an unrectified source of AC voltage which can be used as a signal for an electric tachometer Contact the manufacture of the ...

Page 5: ...he regulator is free from obstructions that restrict air movement around or below the regulator s aluminum heat sink While the regulator is designed to operate safely in conditions 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 The max operating temperature is 90 C Should it be necessary to ins...

Page 6: ... 1 LAMP 17 DASH LAMP MC 620 Regulator Terminal Layout Magnetic Reed Switch 17 16 15 14 13 12 11 10 9 8 7 6 5 1 2 3 4 1 Ground Input 2 12V Power Input 3 12V Ignition Input 4 Field Output 5 Alt Temp 6 Alt Temp 7 Bat 1 Temp 8 Bat 1 Temp 9 48V Battery Voltage Sensor 10 Data TX 11 Data RX 12 Stator In 13 Tach Out 14 Bat 2 Temp 15 Bat 2 Temp 16 Aux 1 Lamp 17 Dash Lamp 48V B B START 12V B L WARNING DO NO...

Page 7: ...S A is required It is NOT included in the harness and must be purchased separately It allows your MC 620 voltage regulator to monitor your alternator temperatures and limit output if safe operating levels are exceeded The MC 620 uses active temperature regulation to maximize high temperature output The MC TS A sensor includes a 54 cable a sensing attachment lug and positive and negative regulator ...

Page 8: ...re When an electric tachometer is used the alternator s stator output will provide the electrical pulse needed to drive the tachometer The MC 620 has been designed to provide regulated tach output when the WHITE stator wire is connected to the regulator s Stator In 12 terminal and the out feed wire to the electric tachometer is connected to the Tach Out terminal 13 terminal Not required for magnet...

Page 9: ...e voltage source 2 Connect the negative terminal on the lamp or audible alert to the Dash Lamp terminal on the regulator 3 When connected the lamp should flash at regulator start up to indicate active status INITIAL PRE FLIGHT TEST AND START UP When the regulator is properly mounted and the regulator wiring is installed the MC 620 is ready for pre flight testing Before turning on the engine it s a...

Page 10: ...voltage for a set time period specified by the battery program selected Factory set values are 55 6 volts for 0 3 hours 18 minutes and are adjustable with Av and A1c respectively See page 16 7 Calculated Absorption Charge Target voltage is maintained at the Absorption Charge level The regulator calculates battery condition by constantly monitoring field duty cycle battery sense voltage and an inte...

Page 11: ...OO HOT OVER 55 C FACTORY DEFAULT E21 BATTERY 2 TOO HOT OVER 55 C FACTORY DEFAULT E22 ALTERNATOR TOO HOT OVER 107 C E24 VOLTAGE REGULATOR TOO HOT OVER 90 C E25 BATTERY 1 TOO COLD E33 BATTERY SENSE DIS CONECTED E41 FIELD VOLTAGE TOO HIGH E42 STATOR VOLTAGE TOO HIGH E51 SMALL ENGINE MODE IS IN OPERATION In addition to the information provided in the basic display shown above the MC 620 long display p...

Page 12: ...hird display digits The RED light indicated activation of 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 BASI...

Page 13: ... specifics Your battery manufacturer may supply you with a C rate for charging and discharging The maximum amount of charging current your battery can safely handle is determined by multiplying the C Rate by the capacity of the bank i e 4x 100Ah 12V batteries rated at 0 5C charge 400 Ah 0 5C 200amps MAX If your alternator is capable of outputting more current at any time or condition than the batt...

Page 14: ...nager b 1 95 Field Max b 2 90 Field Max b 3 85 Field Max b 4 80 Field Max b 5 75 Field Max b 6 70 Field Max b 7 65 Field Max b 8 60 Field Max b 9 55 Field Max Sd Short Display Mode Ld Long Display Mode OFF Stator Output Monitoring OFF ON Stator Output Monitoring ON AP1 AP2 AP3 AP4 AP5 PrA Entering Advanced Programming Looped 3 Times Yes b 0 100 Field Max dLC Start Delay AHL High Voltage Limit CL C...

Page 15: ... b 0 INDICATES BLM OFF b 1 INDICATES BLM SETTING 1 FIELD REDUCTION 5 b 2 INDICATES BLM SETTING 2 FIELD REDUCTION 10 b 3 INDICATES BLM SETTING 3 FIELD REDUCTION 15 b 4 INDICATES BLM SETTING 4 FIELD REDUCTION 20 b 5 INDICATES BLM SETTING 5 FIELD REDUCTION 25 b 6 INDICATES BLM SETTING 6 FIELD REDUCTION 30 b 7 INDICATES BLM SETTING 7 FIELD REDUCTION 35 b 8 INDICATES BLM SETTING 8 FIELD REDUCTION 40 b ...

Page 16: ... scroll upward or downward To reverse the direction of scroll 1 REMOVE the magnet from the reed switch 2 Wait for the mode indicator to be displayed 3 TOUCH HOLD when the mode indicator is displayed The values for that mode will begin to scroll in the opposite direction Continue to HOLD until the desired value is displayed 4 REMOVE the magnet from the RED dot The mode indicator will be displayed a...

Page 17: ...mit Allows user control of regulator s low voltage limit Spans between 10 volts and Fv Dropping below ALL causes Dash Lamp to turn on Default is 50 8 volts in 1 volt increments FbA Field Threshold Bulk and Absorption Controls the field output threshold required to cycle from Bulk to Absorb and Absorb to Float Factory set at 65 of field output Raising FbA shortens calculated bulk and absorption cha...

Page 18: ...51 2V Adjustable with ALL See Page 12 High Battery Voltage 62V Adjustable with AHL See Page 11 High Alternator Temperature 225 F Adjustable with AL1 See Page 12 Requires installation of MC TS A sensor High Battery Temperature 125 F Adjustable with B1L See Page 12 Requires installation of MC TS B sensor Low Battery Temperature 32 F LiFePO4 only not adjustable Alternator Failure No voltage on stator...

Page 19: ...the BLACK ground wire at the regulator as shown in diagram 1 With the ignition turned OFF check voltage on the RED power Voltage Sense Terminal 9 BLUE field and BROWN Ignition wires in the regulator plug Voltages should be as follows RED wire equal to start battery voltage for 12V battery Terminal 9 RED wire equal to battery voltage 48V BLUE wire zero volts BROWN wire zero volts 2 With the ignitio...

Page 20: ...xt 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 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...

Page 21: ...pplication maintenance or modification or b any misuse contrary to the instructions provided with the product or c loss or d malfunctions caused by other equipment or e acts of God Examples of conditions not warranted cracked or broken cases parts damaged by fire water freezing lightning collision theft explosion rust corrosion or items damaged in route to Balmar for repair Balmar s Warranty is vo...

Page 22: ...22 www balmar net Customer Service 1 360 435 6100 x1 Technical Support 1 360 435 6100 x3 Tech Service is available Monday Friday 8 30am 7 30pm EST NOTES ...

Page 23: ...23 www balmar net Customer Service 1 360 435 6100 x1 Technical Support 1 360 435 6100 x3 Tech Service is available Monday Friday 8 30am 7 30pm EST NOTES ...

Page 24: ...world To Find a CDI distribution partner visit www cdielectronics com Both Balmar and CDI Products are manufactured in our ISO 9000 Certified Factory in Huntsville Alabama Please read carefully All policies procedures and instructions are subject to change This guide was prepared to provide information and does not constitute a contract Balmar reserves the right without prior notice to change dele...

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Balmar 96 Series, Installation And Operation Manual

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