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Tech Service is available Monday - Friday (8:30am - 7:30pm EST)

INSTALLATION BY WIRE

NOTE: Must install wires listed on this page for regulator to operate.

INSTALL BLACK GROUND WIRE

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

harness and is factory installed on regulator packages designated with “H” at the end of the model 

number. The other end of the Ground Wire is fitted with a ring terminal connector. In most applications, 

this wire can be connected directly to the alternator’s ground terminal post. For best accuracy ground as 

close to the battery as possible.

 

Both the alternator and regulator must be connected to system ground.

INSTALL RED POWER WIRE

The RED Field Wire #2 in diagram at right is included in the four-wire Ford style plug and is factory 

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

the Power Wire is fitted with a butt connector. This MUST be installed to a 12V battery. DO NOT connect 

This MUST be installed to a 12V battery. DO NOT connect 

to a 48V battery. 

to a 48V battery. When a diode-type battery isolator is used, the power and wire must be connected to 

the battery side of the battery isolator. Power Wire is equipped with 10-amp ATC type fuse. The Power 

Wire must be fused to ensure against damage to the voltage regulator.

INSTALL BROWN IGNITION WIRE 

The BROWN Ignition Wire #3 in diagram at right provides ON/OFF voltage for the regulator. This 

MUST BE  a 12V power source. This wire is included in the Ford-style plug at the regulator end of the 

wiring harness. The other end of the wire is fitted with a butt connector. Typically, the ignition wire is connected to the ON side 

of the ignition switch. This may be at the actual switch, or to a wire in the existing engine wiring loom that delivers switched 

voltage from the ignition switch. In some cases, an oil pressure switch may be used to activate the regulator. In either case, the 

regulator’s ignition wire must see zero volts when the engine ignition is switched off. This must be an isolated switch functioning 

as a relay. Switches with a positive and negative connection will not work. 

INSTALL BLUE FIELD WIRE

The BLUE Field Wire #4 in diagram at right provides regulated current to control alternator output. The wire is included in the 

wiring harness Ford-style plug and is pre-connected at the regulator. At the other end of the wire, you’ll find a ring terminal. 

Attach the field wire to the alternator’s field terminal.

INSTALL ALTERNATOR TEMPERATURE SENSOR

Because of the high-power output of the 96-Series alternators, the use of the Alternator Temperature Sensor (MC-TS-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 plug-in connectors. To install the MC-TS-A:

1. 

Connect the sensor lug to one of the four bolts that hold the alternator’s front and rear cases together. Extend the sensor 

cable to the regulator. The cable can be included within the regulator’s wiring harness, or can be run alongside the harness 

and attached with cable ties.

2. 

Connect the temperature sensor to the Alt. Temp. terminals on the regulator.  It is 

essential that the terminals are connected to the correct pin. Connect the red wire to the 

positive terminal #6 and the black wire to the negative terminal #5. 

INSTALL POSITIVE BATTERY SENSE WIRE (48V)

The included voltage sense wire length is designed to sense at the B+ terminal of the al-

The included voltage sense wire length is designed to sense at the B+ terminal of the al-

ternator. For the most accurate voltage sensing and better charging performance, consider 

ternator. For the most accurate voltage sensing and better charging performance, consider 

extending the voltage sense wire to run directly between the regulator and the 48V battery 

extending the voltage sense wire to run directly between the regulator and the 48V battery 

bank. This method is also used if using a battery isolator, or sensing at another location such as a battery switch (Anywhere 

bank. This method is also used if using a battery isolator, or sensing at another location such as a battery switch (Anywhere 

other than the alternator.)

other than the alternator.)

1. 

Attach the included wiring pigtail with 1-amp fuse to a length of wire of sufficient

 

length to reach the desired sensing 

location. If the length of the wire

 

between the regulator and the sensing location is 8’ or less, a 16-gauge wire is 

satisfactory. If the wire exceeds 8’, increase the wire size to 14 gauge.

2. 

If the batteries are connected to a battery isolator, the positive sense wire must be connected to the battery side of the 

isolator, preferably at the larger of the battery banks. If you do not sense at the battery, use the included sense wire to 

read at the B+ stud at the back of the alternator. It features a ring terminal at the alternator end and a female quick connect 

terminal at the regulator end. This wire is fused at the alternator end with a 1-Amp ATC-type fuse and fuse holder. The wire 
MUST be connected at the (#9) Positive Battery Sense Terminal. To complete installation of the sense circuit 

Crimp the 

included spade terminal to the sense wire and reconnect the spade to the (#9) pin.

Magnetic

Reed Switch

17
16

15

14

13

12

11

10

9

8

7

6

5

1

2

3

4

Magnetic

Reed Switch

17
16

15

14

13

12

11

10

9

8

7

6

5

1

2

3

4

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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