Balmar Max Charge MC-612 Manuals

- 1 - Max Charge MC-612 Installation And Operation Manual I. Introduction The microprocessor-controlled Max Charge MC-612 is the most advanced regulator available. The MC-612 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-612 to your alternator right out of the box. Six additional preset pro- grams support most popular battery types, including standard and deep-cycle flooded batteries, AGM, gel, and Optima (spiral wound) technologies, as well as special settings for systems supplying halogen lighting. An easy- to-use magnetic reed switch delivers quick, precise regulator adjustment. Should your charging system require individualized adjustment, the MC-612 provides additional advanced user-defined programming options. When used with optional alternator and battery temperature sensors, the MC-612 automatically monitors ambi- ent alternator and battery temperatures and compensates by adjusting field output to match conditions. Alarm outputs connect to audible or visual alarms to provide warnings of dangerous system conditions. II. Safety Considerations Before installing your MC-612 marine regulator, please take a moment to consider these guidelines for safe reg- ulator installation. Failure to work safely could result in 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 medication that could impair your judgment or reaction time. 8. Always use the right tool for the job. Improper tool use may damage regulator or your boat, and could result in per- sonal injury. 9. Take time to read the manual. Equipment damage and possible injuries may result from an incomplete understand- ing of the installation and operation of the MC-612 regulator. If you are unfamiliar with marine electrical systems, consult with a licensed marine electrician. I. Introduction ........................................................1 II. Safety Considerations ........................................1 III. Installation Guide............................................2-5 IV. Optional Wiring Connections ........................5-6 V. Regulator Operation ..........................................7 VI. Regulator Display Modes ..................................8 VII. Programming Modes ....................................9-11 VIII. System Troubleshooting............................12-13 IIX. Suggested Wiring Configurations..............14-15 Express Installation Instructions ..........................16 Warranty....................................................................16 TABLE OF CONTENTS - 2 - III. Installation Guide 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 pro- gramming for battery type. Additional information regarding advanced programming adjustments and trou- bleshooting are addressed later in the manual. 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. A. Unpack The Box Your Max Charge MC-612-H regulator kit is packaged with the following items: 1. Max Charge regulator 2. 54” wiring harness w/ fuse (10A) on RED power wire 3. Fused (1A) battery sense wire pigtail 4. Magnetic programming tool 5. Installation and operation manual 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-612, without the “H” designation, your kit will not include the wiring harness or fused battery sense pigtail. 1 2 3 4 5 B. Locate And Mount The Regulator Choosing a mounting location for your voltage regulator should be deter- mined 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 heat aluminum heat sink. Should it be necessary to install the regulator further than the harness’s 54” length from the alternator, ensure that any wire extensions are prop- erly connected, as resistance in the harness wiring can reduce charging efficiency or hamper the regulator’s ability to accurately respond to bat- tery conditions. If harness length must reach beyond approximately eight feet, replace the existing harness wires with larger gauge wire. C. Basic Wiring Installation (Topics D to K) 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 Ground (BLACK) and Stator (WHITE) wire. The proper terminal connection points for these, and additional wiring con- nections, are illustrated on the pin location legend shown and discussed on the following pages. - 3 - MC-612 Regulator Layout 1. Magnetic Reed Switch - Activated by placing magnetic tip of programming tool against one or the other end. See illustration in “Programming” section later in this manual. 2. Positive Sense Wire - Connects to independent fused wire included with regulator. Wire must see battery voltage directly for proper operation. See details in text. 3. Ground (Independent) - Connects to individual ground (BLACK) wire in wiring harness. Pre- connected at factory in regulator packages with harness included. 4. Ground (BLACK) - Included in Ford-style plug. 5. Power (RED) - Supplies power to operate the regulator and delivers field current to excite alternator. Included in Ford-style plug. 6. Ignition (BROWN) - Serves as “ON/OFF switch” for regulator. Must see zero volts when enging ignition is off and battery voltage when the igni- tion is on. May also be activated by an oil pres- sure switch. Included in Ford-style plug. 7. Field (BLUE) - Supplies amperage to the alter- nators brushes to excite the regulator. The regu- lator will increase or decrease voltage/amperage on the field to maximize charging without exceeding safe operating voltages. Included in Ford-style plug. 8. Digital Numeric Display - Three-digit numeric dis- play provides an easy-to-use interface for operational and programming modes. 9. Stator Input - Connects (WHITE) stator input from alternator to tach output to electric tachometer. When the tachometer is connected to the alternator via the regulator’s Stator Input and Tach Output (#10), the regulator will automatically enable a min- imum field current value, which will minimize tach bounce when the batteries reach full charge. 10. Tach Out - Connects alternator stator output to an electric tachometer via the regulator. See informa- tion above. 11. Data RX - Not currently used. Provides input connec- tion for planned remote display. 12. Data TX - Not currently used. Provides output con- nection for planned remote display. 13. Alternator Temperature Sensor - Positive and nega- tive terminal pins for use with optional Alternator Temperature Sensor (MC-TS-A). When connected, the temperature sensing function allows the regula- tor to respond to over-temperature conditions at the alternator by reducing field output to the alternator. Reducing field output reduces load on alternator and belts, allowing the alternator to cool down. In addi- tion, the regulator activates the Dash Lamp terminal (#17) so a warning lamp or audible alarm can be used to indicate an over-temperature condition. 14. Battery #2 Temperature Sensor - Indicates over- temperature condition at secondary battery bank, when used with optional Battery Temperature Sensor (MC-TS-B). Regulator discontinues field cur- rent to the alternator when high battery temperature is sensed. Activates Dash Lamp (#17) when condi- tion is indicated. 15. Battery #1 Temperature Sensor - Automatically compensates for changes in ambient battery temper- ature when used with optional Battery Temperature Sensor (MC-TS-B). Regulator discontinues field cur- rent to the alternator when high battery temperature is sensed. Activates Dash Lamp (#17) when condi- tion is indicated. 16. Aux. 1 Output - Terminal goes to ground when the following conditions occur: alternator output at full capacity, Small Engine Mode activated, Equalization Mode activated. Can be connected to ground side of lamp or audible alert device. 17. Dash Lamp - Terminal goes to ground when the fol- lowing conditions occur: low system voltage, high system voltage, high alternator temperature, high battery temperature. Can be connected to ground side of lamp or audible alert device.

- 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. Its Universal FFactory PProgram aallows yyou tto cconnect tthe M MC-6612 to yyour aalternator rright oout oof tthe bbox. 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: (360) 435-6100 FAX: (360) 435-3210 E-MAIL: [email protected] WEB: WWW.BALMAR.NET Max Charge MC-612 Regulator Installation and Operator’s 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. - 2 - Figure 11 - Regulator wiring attachment. Figure 22 - Wire size chart. Represents 3% voltage drop. Lengths should be measured in round trip. Figure 33 - Regulator terminal layout. 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 - 3 - 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. Figure 44 - Proper attachment of optional battery and alternator temp sensors at the regulator. Figure 55 - Mounting temperature sensor mid-case on small case alter- nator. Figure 66 - Mounting temperature sen- sor 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) Aux. #1 (Advisory) Output (-) 0.5 amp - when in alarm mode • Alt. output at full capacity • Small engine option activated (051) • Equalization mode activated Figure 77 - Alarm output functions.