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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)

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 

qualified marine electrical technician.

Regulator Installation

The following information is intended to provide the installer with the basic information required to complete 

installation. This section of the installation manual will deal with mounting, wiring connections and basic 

programming for battery type. Additional information regarding advanced 

programming adjustments and troubleshooting are addressed later in the 

manual.

Unpacking the Box

Your Max Charge MC-624-H regulator kit is packaged with the following items:

•  Max Charge MC-624 Regulator

•  54” Wiring Harness

•  Fused (1A) Battery Sense Wire Pigtail

•  Magnetic Programming Tool

•  MC-624 Quick Start Guide

If any of the listed items is not included with your regulator kit, call our customer 

service department at 360-435-6100. Please note - If your regulator box is marked Max Charge MC-624, 

without the “H” designation your kit will not include the wiring harness or fused battery sense pigtail.

Locate And Mount The Regulator

Choosing a mounting location for your voltage regulator should be determined based on the following 

factors; distance from alternator, distance from inverters, transmitters and other sources of RF noise, 

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

a three to four foot radius for mounting. Ample airflow is essential for the regulator’s proper operation. 

Ensure that the regulator is free from obstructions that restrict air movement around or below the regulator’s 

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 install the regulator further than 54” from the alternator, ensure that any wire 

extensions are properly connected, as resistance in the harness wiring can affect charging efficiency. If 

harness length must reach beyond approximately 8’, replace the RED power and BLUE field wires with 

larger gauge wire that’s sized to ensure voltage drop < 3%.

Basic Wiring Installation

The regulator’s wiring harness includes six wires required for standard installation. Four of those wires are 

connected to the regulator via a Ford-style plug connector that’s pre-installed on the regulator. These wires 

include the Ground (BLACK), Power (RED), Ignition (BROWN), and Field (BLUE). Plug is shown at right.
In addition, the harness includes a separate Stator (WHITE) wire. The proper terminal connection points for 

this, and additional wiring connections, are illustrated on the pin location legend shown and discussed on 

the following pages.

Summary of Contents for Max Charge MC-624

Page 1: ...g your regulator 2 Remove loose fitting clothing or jewelry which could become entangled in your motor or other machinery prior to installing regulator 3 Wear ANSI approved safety eye wear and protect...

Page 2: ...tors distance from alternator distance from inverters transmitters and other sources of RF noise convenient access and readability of the display The regulator wiring harness is 54 inches long providi...

Page 3: ...th your battery manufacturer for 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...

Page 4: ...4 FIELD OUTPUT 5 ALT TEMP 6 ALT TEMP 7 BAT 2 TEMP 8 BAT 2 TEMP 9 BAT 1 TEMP 10 BAT 1 TEMP 11 DASH LAMP 12 GROUND INPUT Magnetic Reed Switch 1 2 3 4 5 6 8 9 10 11 12 7 Ignition Connector 1 Connector 2...

Page 5: ...plug which is pre installed on the voltage regulator When the tachometer is connected via the MC 624 the regulator will ensure that the tachometer will not discontinue supplying field current when the...

Page 6: ...e sensor lug to the battery negative post closest to the center of the battery bank Extend sensor cable to the regulator 2 Connect the temperature sensor to the Bat 1 Temp terminals on the regulator I...

Page 7: ...operly mounted and the regulator wiring is installed the MC 624 is ready for pre flight testing Before turning on the engine it is advisable to check voltages at the following terminal connections to...

Page 8: ...are met 5 Ramps down to Absorption voltage 6 Absorption Charge Regulator continues to control the alternator s output voltage for an additional 18 minutes at approximately 2 10 s of a volt below bulk...

Page 9: ...ar 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 Regulator Programming Flow Chart More details can be found on pa...

Page 10: ...s Standard Flooded Halogen Systems Lithium Yes Yes Yes Yes Yes Balmar Alternator Models 6 Series Alternators 70A 150A Yes Yes Yes Yes Yes Yes AT Series Alternator 165A 200A Yes Yes Yes Yes 9 Series La...

Page 11: ...ENGINE MODE IS IN OPERATION E52 BELT LOAD MANAGER IS IN OPERATION In addition to the information provided in the basic display shown above the MC 624 long display provides the following data The long...

Page 12: ...e reed switch then releasing the reed switch be removing the magnet from the RED dot on the epoxy potting Basic Programming Programming For Battery Type The MC 624 features selectable programs for SEV...

Page 13: ...ramming mode The Advanced Programming Modes are as follows dLc Start Delay Controls time from regulator activation to start of charging Factory preset at one second Adjustable to a maximum of 999 seco...

Page 14: ...me the batteries will be held at equalization voltage Maximum time adjustment is three hours If manufacturer guidelines require longer equalization times allow for maximum time and reset for additiona...

Page 15: ...ery Temperature 125 F Requires installation of MC TS B sensor cable System Troubleshooting Regulator Troubleshooting The majority of charging difficulties can be attributed to damage corrosion or wear...

Page 16: ...FOR FIELD OUTPUT TO OCCUR ENSURE THAT VOLTAGE IS ABOVE 22V WHEN TESTING SYSTEM If voltage is not present on the RED or BROWN wires the regulator will not work If voltage is as expected at the RED and...

Page 17: ...y longer than necessary to detect charging If the system is not charging remove the alternator and have it inspected by a qualified alternator shop or call Balmar for warranty evaluation To test the a...

Page 18: ...18 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 19: ...plication 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 conditio...

Page 20: ...he 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...

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