BALMAR MC-618 Alternator Regulator User Manual

MC-618
Alternator Regulator
Installation & Operation Manual

SUP-0283 REV C.

Introduction

The Balmar Max Charge MC-618 is the latest generation of smart, multi- stage Balmar Max Charge voltage regulators. Designed to provide precise voltage control for Balmar’s high-output 12-volt alternators and other externally regulated P-type alternators, the MC-618 features user-selectable programs for the following battery types: Deep-cycle flooded, standard flooded, gel, AGM, spiral wound AGM, Carbon Foam and LiFePO, batteries. The regulator also features a universal default program that’s designed for use in vessels utilizing voltage-sensitive halogen equipment.

In addition to the user-selectable preset programs, the MC-618 features a wealth of advanced programming modes which make it possible to tailor charging to a wide variety of environments.

When used in conjunction with optional MC-TS-A and MC-TS-B alternator and battery temperature sensors, the MC-618 fea­tures the ability to monitor and respond to a range of ambient temperature conditions, including reduction or discontinuation of charging voltages, should a catastrophic over-temperature condition occur at the alternator or the batteries. It can also protect Lithium batteries from being charged when the temperature falls below freezing.

When connected to an SG200 Battery monitor via SmartLinkThl, The following is available from the SG200’s Color Display: I. MC-618 real-time operating data

2. Battery Type selection (Basic Programming)
3. Adjustment of the Maximum Field % (Belt Load Manager)

When an SG2-0300 Bluetooth Gateway is used in conjunction with the SG200 + MC-618 even more features are unlocked via the Balmar App:

1. Real-time monitoring of the MC-618 performance
2. Full Basic and Advanced Programming from a phone or tablet
3. Save and Load program settings

Safety Considerations

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 prior to installing the regulator.
3. Wear ANSI-approved safety eye-wear and protective gear.
4. DO NOT attempt to modify the regulator. 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 initiating the installation.
7. DO NOT attempt regulator 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 the regulator or your vessel 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-618 regulator. If you are unfamiliar with electrical systems, consult with a licensed marine or mobile electrician.

Regulator Installation

CAUTION: The following instructions are intended for use by experienced electrical installers. If you are not experienced at installing electrical system components, we recommend the use of a qualified marine electrical technician.

These instructions are intended to provide the installer with the basic information required to complete the 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 is addressed later in the manual.

Unpacking the Box

Your Max Charge MC-618-H regulator kit is packaged with the following items:

• Max Charge MC-618 Regulator
• 54″ Wiring Harness
• Fused Battery Sense Wire Pigtail
• Magnetic Programming Tool
• MC-618 Quick Start Guide

If any of the listed items are not included with your regulator kit, call our customer service department at +1-360-435-6100. Please note – If your regulator box is marked Max Charge MC-618, without the ‘hi” designation your kit will not include the wiring harness but does include the fused battery sense pigtail.

NOTE: If connecting the MC-618 to a SmartLink™ network/SG200 battery monitor, a SmartLink”‘ Cable (Not Included) is needed. The SG2-0400 is 10 meters long, and the SG2- 0403 is 5 meters in length. Both include the SG2-0404 SmartLink™ Cable Adapter

Locate And Mount The Regulator

Choosing a mounting location for your voltage regulator should be determined based on the following factors; distance from the 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. A 120″ harness is also available from Balmar (Part # 1020.) 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 >120″ from the alternator, and 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 10′, 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 five wires required for standard installation. Four of those wires are connected to the regulator via a Ford- style plug connector that’s preinstalled on the regulator. These wires include the Ground (BLACK), Power (RED), Ignition (BROWN), and Field (BLUE). The plug is shown on right.

In addition, the harness includes a separate Stator (WHITE) wire. This is used in some installations to provide a signal used to drive a tachometer. 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.

MC-618 Regulator Terminal Layout

1. GROUND INPUT
2. POWER INPUT
3. IGNITION INPUT
4. FIELD OUTPUT
5. ALT. TEMP. (-)
6. ALT. TEMP. (+)
7. BAT. TEMP. #1 (-)
8. BAT. TEMP. #1 (+)| 9. POSITIVE VOLTAGE SENSE
10. SmartLink™ TX
11. SmartLink™ RX
12. STATOR IN
13. TACHOMETER OUT
14. BAT. #2 TEMP. (-)
15. BAT. #2 TEMP. (+)
16. AUX. #1 LAMP
17. DASH LAMP
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Installation by Wire

NOTE: Must install wires listed on this page for the regulator to operate. Install BLACK Ground Wire

The BLACK Ground Wire #1 in the diagram at the 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 some 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, especially when charging lithium batteries. Both the alternator and regulator must be connected to the system ground.

Install RED Power Wire
The RED Power Wire #2 in the diagram at the 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 ring terminal connector. In most applications, this wire can be connected directly to the alternator’s positive output post. When a diode- type battery isolator is used, the power and voltage sense (#9) wires must be connected to the battery side of the battery isolator. The Power Wire is equipped with a 15-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 the diagram at right provides ON/OFF voltage for the regulator. 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.

Install BLUE Field Wire
The BLUE Field Wire #4 in the diagram at the right provides a regulated current to control the alternator output. The wire is included in the wiring harness’ Ford-style plug and is preconnected at the regulator. At the other end of the wire, you’ll find either a plug or a ring terminal, depending on the alternator’s field terminal connection. Attach the field wire to the alternator’s field terminal.

Install Alternator Temperature Sensor
The optional Alternator Temperature Sensors (MC-TS-A or MC-TS-A80) allow your MC-618 voltage regulator to monitor your alternator temperatures and limit output if safe operating levels are exceeded. The MC-618 uses active temperature regulation to maximize high-temperature output. The sensor includes a 54″ (MC-TS-A) or 80″

(MC-TS-A80) cable, a sensing attachment lug, and positive and negative regulator plug-in connectors. To install either sensor:

1. Connect the sensor lug to one of the four bolts that hold the alternator’s front and rear cases together. If a Balmar alternator is installed use the predrilled location provided on the rear case. 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 to the cable
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 Sense Wire
Included with the MC-618 wiring harness kit is a fused wiring pigtail that features a ring terminal at one end and a butt connector at the other. In the center is an ATC-type fuse and fuse holder. This wire MUST be connected at the (#9) Positive Battery Sense Terminal. A female quick connect plug has been pre-attached to the terminal (#9) pin. To complete installation of the sense circuit:

1. Identity is the favored location for battery sense.

NOTE: The voltage sense wire MUST be installed on the alternator side of any disconnect device. If a disconnect on the positive output cable of the alternator occurs — such as a fuse blowing or a disconnect switch — the sense wire must read the alternator output voltage and not the battery voltage. If the alternator is disconnected from the battery and the regulator is sensing the battery voltage, it will continue to output power, likely causing alternator damage. This Is not covered under warranty.

2. Attach the included wiring pigtail with a 10-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.
3. Remove the female 1/4″ spade terminal from the terminal (#9) pin. Crimp the spade terminal to the sense wire and reconnect the spade to the (#9) pin.

Install Battery #1 Temperature Sensor
The optional Battery Temperature Sensor (MC-TS-B) allows your Max Charge MC-618 voltage regulator to monitor your battery bank for changes in battery temperature, adjust charging voltages to compensate for battery temperature, and respond to a battery over-or-under-temperature condition by discontinuing charging. The MC-TS-B sensor includes a 20′ cable, a sensing attachment lug, and positive and negative regulator plug-in connectors. To install the MC- TS-B:

1. Connect the sensor lug to the battery negative post closest to the center of the battery bank. Extend the sensor cable to the regulator.
2. Connect the temperature sensor to the Bat. #1 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 (#8) and the BLACK wire to the negative terminal (#7).

NOTE: Do not crush, crimp or bend the portion of the sensing lug covered by heat shrink tubing. Doing so can destroy the sensor and is not covered by a warranty.

Install WHITE Stator – In And Tach – Out Wires

When an electric tachometer is used, the alternator’s stator output will provide the electrical pulse needed to drive the tachometer. The MC-618 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 outfeed wire to the electric tachometer is connected to the Tach Out terminal (#13) terminal. Not required for magnetic pick-up tachs.

Stator output can also be used to detect alternator failure. See Page 10 for details.

When the tachometer is connected via the MC-618, the regulator will ensure that the tachometer will not discontinue supplying field current when the batteries are fully charged. When connecting the tachometer to the alternator stator output, it will be necessary to determine the number of poles in the alternator in order to properly adjust your tachometer. Most Balmar alternators feature 12-pole rotors and stators, though, in some cases, the pole count maybe 14 or 16. See the alternator manual for specifics. See your tachometer manual for adjustment instructions.

Install Battery #2 Temperature Sensor
Your Max Charge MC-618 voltage regulator can accommodate a secondary battery temperature sensor. Used in conjunction with an optional MC-TS- B battery temperature sensor, the regulator can monitor temperature at a secondary battery bank and respond to a battery over-temperature condition by discontinuing charging.

To install a secondary battery temperature sensor:

1. Connect the temperature sensor to the secondary battery bank following the directions provided for the primary battery temperature sensor.
2. Connect the temperature sensor to the Bat. #2 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 (#15) and the BLACK wire to the negative terminal (#14).

Install Aux. 1 Lamp

The Max Charge MC-618 regulator’s Aux. #1 (#16) terminal provides the ability to use a visual indicator when the regulator is operating under the following conditions: Full-field (the alternator is working at full power) and Small Engine Mode (the regulator is being controlled at 50% field output). When a described condition is detected, the regulator sends the Aux. #1 terminal from neutral to ground. To utilize the Aux. #1 Lamp function:

1. Connect a small LED or incandescent lamp (maximum current flow is 500 mA) to a positive voltage source.
2. Connect the negative terminal on the lamp to the Aux. #1 terminal on the regulator.

CAUTION: Reversing the polarity of the battery or alternator temperature sensors will damage the sensor and is not covered by a warranty. Ensure that the connections are correct, and never re-connect with the regulator powered.

Install Dash Lamp

The Max Charge Dash Lamp (#17) terminal provides the ability to activate a visual or audible indicator when the regulator monitors the following conditions: Low system
voltage, high system voltage, high alternator temperature, high battery temperature (temperature conditions are only indicated when appropriate temperature sensors are
connected) and no voltage on the stator, indicating that the alternator has failed. When a described condition is detected, the regulator sends the Dash Lamp terminal from
neutral to ground. To utilize the Dash Lamp function:

1. Connect a small LED or incandescent lamp, or a (piezo) alert (maximum current flow is 500 mA) to a positive 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.
   Install SmartLink™ Adapter
   If you wish to connect the MC-618 to a SmartLinkTM network, this is done via the SmartLinkTM Adapter, part # SG2-0404 It is included in the MC-618H kit, but not if you purchased the regulator without a harness. The two fast-on connectors shown here to the left are connected to pin 10 and 11 on the regulator. Of the two Deutsch-style connectors on the right side, only one is used in a single MC-618 installation. In all instances, it is connected to an existing SmartLinkTM device using a SmartLinkTM cable (SG2-0400, not included) between that device and the adapter. NOTE: For more SmartLinkTM installation instructions, see the SG200 Manual

NOTE: A Color Display CAN NOT be plugged directly into the SmartLinkTM adapter cable without a SmartShunt on the network. The SmartShunt is needed to power the Network. The display will not function without this power.

NOTE: When Two regulators are used on a single SmartLink™ Network, the Device ID of one regulator MUST be set to “B” See the basic programming section entitled “Programming the SmartLink™ Device ID” for more information

Initial Preflight Test And Start-Up
When the regulator is properly mounted and the regulator wiring is installed, the MC-618 is ready for preflight testing. Before turning on the engine, it’s advisable to check voltages at the following terminal connections to ensure that the wiring is correct.
Test #1 verifies proper voltage values with the regulator turned off. Test #2 verifies the expected voltages with the regulator turned on.

Note: If the regulator’s BROWN ignition wire is receiving its switched source of voltage from an oil pressure switch, it may be necessary to start the engine before applying test #2. If the engine must be run to accomplish test #2, be sure that the alternator is properly cabled on both positive and negative sides to the battery being charged. Failure to do so could result in damage to the regulator and alternator.
Using your hand-held multimeter, test the following wiring terminals for voltage:

TEST #1: Engine/Ignition Off

• Primary RED Power Wire (Terminal #2) >12V
• Positive Voltage Sense Wire (Terminal #9) >12V
• BROWN Ignition Wire (Terminal #3) 0V
• Primary BLUE Field Wire (Terminal #4) 0V

TEST #2: Engine/Ignition ON

• Primary RED Power Wire (Terminal #2) >12V
• Positive Voltage Sense Wire (Terminal #9) >12V
• BROWN Ignition Wire (Terminal #3) >12V
• Primary BLUE Field Wire (Terminal #4) 4-12V

Regulator Operation

The MC-618 regulator’s microprocessor-controlled charging system uses a sophisticated, multi-stage profile to deliver maximum charging output while protecting the batteries from overcharging damage. When the regulator is first turned on, the processor performs a quick one-second self-diagnostic assessment. Following that diagnostic, the MC-618 initiates the selected battery charge program. Note that the Factory-set default values mentioned below correspond to the UFP battery program which is enabled by default. The battery program is as follows.

1. Start Delay. Controls time between regulator activation and the start of charging. Factory set at one-second User adjustable with DLC (See page 14).
2. Sort Ramp. Gently increases target voltage from current battery resting voltage to the Bulk Charge stage target at a fixed rate of 0.04 volts per second. This stage typically takes 1-2 minutes to complete.
3. Bulk Charge. The most aggressive of the charging stages. Target voltage is held to a preset level for a set time period, both of which are defined by the battery program selected. As the battery charges, the voltage rises to meet and hold the Target factory-set values are 14.1 Volts for 0.3 hours (18 minutes), and are adjustable with by and b1 c, respectively (See page 14).
4. Calculated Bulk Charge. Target voltage is maintained at the Bulk level. The regulator calculates battery condition by constantly monitoring the field duty cycle, battery sense voltage, and an internal timer. Depending on these conditions, the regulator will stay in the Calculated Bulk stage for between 2 seconds and a fixed 6-hour time limit. If the 6-hour limit is exceeded it will automatically transition to the following stage. The field duty cycle target (FBA) is user adjustable. Factory set default is 65% (See page 15).
5. Ramp to Absorption. Gradually changes the target voltage from the current battery sense voltage to the Absorption Charge stage target at a fixed rate of 0.02 volts per 7 seconds This stage typically takes 1 minute to complete.
6. Absorption Charge. The alternator output is held at a set voltage for a set time period, specified by the battery program factory-set values are 13.9 volts for 0.3 hours (18 minutes) and are adjustable with Av and Alc, respectively (See page 14).
7. Calculated Absorption Charge. Target voltage is maintained at the Absorption Charge level. The regulator calculates battery condition by constantly monitoring the field duty cycle, battery sense voltage, and an internal timer. Once all conditions are met, the regulator will transition to the next stage. The time duration of this stage is between 2 seconds and 6 hours, depending upon battery condition. If the 6-hour limit is exceeded the regulator will automatically transition to the following The field duty cycle target (FBA) is user adjustable. Factory set default is 65% (See page 15).
8. Ramp to Float. Gradually changes the target voltage from the current battery sense voltage to the Float Charge stage target at a fixed rate of 0.02 volts per 3 seconds. This stage typically takes about 1 minute to complete.
9. Float Charge. The alternator output is held at a preset voltage for a set time period, again, specified by the battery program Factory-set defaults are 13.4 volts for 0.3 hours (18 minutes), adjustable with Fv and Pic, respectively (See pages 14 & 15).
10. Calculated Float Charge. Target voltage is maintained at the Float level. The regulator can respond to an increased charge demand by reverting to the Absorption Charge stage if the conditions warrant it. The battery condition is judged by constantly monitoring the field duty cycle, battery sense voltage, and an internal timer. The regulator will stay in the Calculated Float charge stage for a minimum of 2 seconds and up to 6 hours. If the 6-hour limit is exceeded the regulator will automatically revert to the absorption charge stage. The field duty cycle threshold (FFL) is user adjustable Factory set default is 65% (See page 15).

Regulator Programming Methods

With the introduction of the MC-618, there are now three ways to program your regulator

1. Using the Magnetic Reed Switch and the Balmar Programming Tool (Magnetic Screwdriver) Just like the superseded model MC-614
2. The SG200 Color Display (Basic, but not Advanced Programming)
3. With an SG200 AND SG2-0300 Bluetooth® Gateway, you can perform Basic and Advanced Programming via the Balmar App

Using the SG200 Color Display

When connected to the SmartLink™ Network, the Color Display of the SG200 may be used to:

1. Perform Basic programming by selecting a Battery Profile
2. Turn the Alternator Failure Advisory on/off (Shows on Regulator display only)
3. Set the regulator display to long/short mode
4. Change the Max Field Percentage of the regulator when operating. In previous regulators, this was known as Belt Manager For more information on how to use the Color Display to change MC-618 settings, see the SG200 manual.

NOTE: When a battery program is changed, all settings under Advanced Settings will be replaced with the new battery program’s default settings. This means that any changes to advanced settings previously made will be erased.

Using the Bluetooth® Gateway (SG2-0300 optional) and the Balmer App

The Bluetooth® Gateway can be used to connect the Balmar App to all devices on the Smar­tLinkTM Network. When connected to the SmartLink” Network and the MC-618, the Balmar App may be used to:

1. Monitor the real-time performance of the MC-618 regulator
2. Perform Basic Programming by selecting a Battery Profile
3. Create, save and load Advanced Programming configurations

NOTE: The Bluetooth® Gateway CAN NOT be connected directly to the
MC-618, as the regulator, cannot power the Bluetooth® Gateway. The
MC-618 must be connected to a SmartLink™ network, typically an SG200 Battery Monitor.

NOTE: For more information on using the Balmar App to program and monitor the MC-618, please visit our website.

Preset, Multi-Stage Battery Programs

Part Number:

| Balmar Regulators| Digital Duo Charge| Dual Engine Centerfielder
---|---|---|---
12 Volt| 24 Volt
ARS-5| MC-618| MC-612-DUAL| MC-624| DDC-12/24| CFII-12/24
Universal Factory Program, Deep CycleFlooded, Gel Cell, Absorbed Glass Mat (AGM) and Spiral Wound Flooded (Optima)| Yes| Yes| Yes| Yes| Yes| Yes
Standard Flooded, Halogen Systems, Lithium| –| Yes| Yes| Yes| Yes| Yes
Carbon Foam AGM| | Yes| | | |
Balmar Alternator Models
6-Series Alternators (70A-150A)| Yes| Yes| Yes| Yes| Yes| Yes
XT/AT-Series Alternators (165A-250A)| –| Yes| Yes| –| Yes| Yes
9-Series Large Case Alternators (140A-310A)| –| Yes| Yes| Yes| Yes| Yes
Multiple Alternator/Engine Configurations
Dual Engine, One Alternator Each| –| Yes (qty 2)| –| Yes (qty 2)| Yes| Yes
Single Engine, Two Alternators| –| –| Yes| Yes (qty 2)| Yes| Yes

*Requires a Centerfielder II, (Part # CFII-12/24)

Regulator Display Modes – Short Display / Long Display

The regulator’s three-digit alphanumeric LED display provides a scrolling view of the charging status. Under normal operation, the display will indicate the following:
Regulator Display Modes – Short Display / Long Display

References

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