Owners manual

ManualsBrandsBalmar ManualsBoatingAT Series Alternator - Spindle Mount(Single Foot) - 165A - 12V

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INTRODUCTION

Thank you for choosing a Balmar high-output alternator. This alternator is uniquely

designed to provide the nest performance and durability for your vessel.

When used with a Balmar multi-stage regulator, your alternator can provide even greater efciency when charging

deep-cycle ooded, standard ooded, gel, AGM, Optima and other marine battery technologies. When preset

for your battery type, the smart regulator will guide your alternator through a charging program that’s tailored to

provide your batteries with the best care possible.

SAFETY CONSIDERATIONS

Before installing your new alternator, please take a moment to

consider the following guidelines for safe alternator installation

and operation. Failure to follow these guidelines could result in

injury or damage to your vessel’s electrical system.

1. Always disconnect your batteries and turn your battery

switches to their “OFF” positions prior to installing your al-

ternator.

2. Remove any loose tting clothing or jewelry which could

become entangled in your motor or other machinery.

3. Wear ANSI-approved safety glasses or eye wear.

4. Ensure that the engine has cooled sufciently before begin-

ning installation.

5. DO NOT install your high-output alternator without ensuring

that system wiring is sufcient to handle increased amper-

age loads.

6. Be sure that your work area is properly ventilated and that

no fuels or solvents are present in and around your work

area.

7. DO NOT operate your charging system without proper fus-

ing. Failure to do so could result in severe injury and/or

damage or loss of your vessel. DON’T take chances with

fusing.

8. DO NOT attempt installation while using alcohol or medica-

tions which could impair your judgement or reaction time.

9. Use the right tool for the job. Use of improper tools could

result in damage or injury.

10. Take time to read the manual. Equipment damage and

possible injury may result from an incomplete understand-

ing of the proper installation and use of the alternator.

CAUTION: The following instructions are intended for use by

experienced marine electrical installers. If you are not suf-

ciently experienced with marine electrical systems, we recom-

mend a qualied electrician be used for installation.

ALTERNATOR INSTALLATION

AND OPERATION MANUAL

CONTENTS

INTRODUCTION ................................................1

SAFETY CONSIDERATIONS ..............................1

ALTERNATOR MOUNTING STYLES ..................2

ALTERNATOR INSTALLATION ISSUES .............2

SIZING BATTERY CABLES ................................3

BELT SIZE REQUIREMENTS .............................3

BELT TENSION ..................................................3

FAN ROTATION ..................................................3

GROUNDING ......................................................3

PULLEYS ...........................................................4

ALTERNATOR HEAT ..........................................4

FUSING .............................................................. 4

ALTERNATOR-TO-BATTERY RATIOS ................. 4

MULTIPLE BANK CHARGING OPTIONS ............5

BATTERY SWITCHES ........................................5

BATTERY COMBINERS/SOLENOIDS .................5

BATTERY ISOLATOR .........................................5

DIGITAL DUO CHARGE ......................................6

TWO ALTERNATORS-SINGLE ENGINE ..............6

TWIN ENGINE ISSUES ......................................7

CENTERFIELDER ............................................... 7

INSTALLATION ISSUES BY ALTERNATOR ........8

6-SERIES ALTERNATORS ...............................8-9

AT-SERIES ALTERNATORS ..............................10

94 & 94LY-SERIES ALTERNATORS .................11

95-SERIES ALTERNATORS ..............................11

97-SERIES ALTERNATORS ..............................12

97EHD-SERIES ALTERNATORS .......................12

98-SERIES ALTERNATORS ..............................13

SYSTEM TROUBLESHOOTING ...................14-15

WARRANTY .....................................................16

Summary of content (16 pages)

PAGE 1
ALTERNATOR INSTALLATION AND OPERATION MANUAL INTRODUCTION Thank you for choosing a Balmar high-output alternator. This alternator is uniquely designed to provide the finest performance and durability for your vessel. When used with a Balmar multi-stage regulator, your alternator can provide even greater efficiency when charging deep-cycle flooded, standard flooded, gel, AGM, Optima and other marine battery technologies.
PAGE 2
ALTERNATOR MOUNTING STYLES Due to the large number of engine makers and engine models, Balmar cannot guarantee a drop-in replacement for every application. We recommend installing the alternator model that most closely matches your existing alternator. Your installer may have to adapt the basic mounts to fit your needs. The majority of marine engines are equipped with one of four alternator mounting styles. The following describes which alternator represents each specific mounting style: 1.
PAGE 3
SIZING BATTERY CABLES 12-VOLT CABLE SIZE CHART Battery cable size must meet the increased output capacity of your new alternator. The easiest method for determining the best cable size for your system is to compare your new alternator’s rated amperage output and the ROUND TRIP length of the cable running from the alternator to the battery being charged, and back to the alternator via ground to the chart at right. Length/Ft.
PAGE 4
PULLEYS Most small case alternators rated at 110 amps or less come standard with a single groove 2.5" deep vee pulley. The deep vee pulley is designed to provide optimal power transfer for belts measuring 3/8" (10mm) to 1/2” (13mm), as measured across the back of the belt. Keep in mind, 3/8" and 7/16" belts may sit low in the pulley sheave. This will not adversely affect the belt’s performance.
PAGE 5
MULTIPLE BANK CHARGING OPTIONS When charging a single starting battery, the alternator can be connected to the battery directly, or via an ON/OFF switch. More typically, in a marine system, the alternator will be supporting a smaller starting battery and larger house battery bank -- or a starting battery, along with multiple banks for house loads, inverter loads, windlass or thruster.
PAGE 6
DIGITAL DUO CHARGE Balmar’s Digital Duo Charge connects between the house and start (secondary) batteries -- keeping the two banks separate until the unit senses 13 volts (26@24V) at the house battery. Once voltage is reached, the Duo Charge supplies up to 30A to the secondary bank. Voltage is regulated at the secondary bank based on a preset program chosen by the user to reflect the secondary battery type. Standard and deep cycle flooded, gel and AGM battery types are supported.
PAGE 7
TWIN ENGINE ISSUES Twin engine applications pose some unique challenges in addressing battery needs. Some primary charging configurations are as follows: 1. Dedicate Alternator #1 to charge engine starting batteries. Dedicate Alternator #2 to the house battery bank. 2. Combine outputs from Alternator #1 and Alternator #2 to provide increased charging amperage for the main (house) battery bank, and supply the engine (and other secondary) batteries via Digital Duo Charges or combiners.
PAGE 8
INSTALLATION ISSUES BY ALTERNATOR SERIES 6-SERIES ALTERNATORS Six-Series models are among the most frequently installed Balmar alternators. Designed to replace a wide range of OEM alternators on most common marine gasoline or diesel engines, 6-Series alternators feature three mounting styles; • 60-Series models, which feature a saddle mount with a 3.15" space between front and rear mounting feet. • 621-Series models, which feature a single-foot (spindle) mount.
PAGE 9
USING THE SMARTREADY® INTERNAL VOLTAGE REGULATOR The 6-Series alternator is unique among Balmar alternators, in the fact that it is equipped with a single stage Smart Ready® internal regulator. Designed to be used as a stand-alone or emergency spare, the Smart Ready regulator can be wired, as shown at right, to take over in the case of an external regulator failure.
PAGE 10
AT-SERIES ALTERNATORS – 165A Advanced Technology (AT-Series) alternators are available in three mounting configurations: • SF models: 1" or 2" single foot. • DF models: 3.15” ID saddle mount • AT-Series alternators are isolated ground, externally regulated, and feature 16 stator poles. Field and stator terminals are included in a pigtail included with the alternator. Terminal connections are as follows: 3 4 1 2 1.
PAGE 11
94-SERIES & 94LY-SERIES ALTERNATORS Large case 94-Series alternators are designed to provide 165 or 210 amps at 12 volts, or 140 amps at 24 volts. Mounting is a 2” single-foot Delco-style mount. Alternators in the 94-Series feature isolated ground terminals, external regulation and 12-pole stator output. 3 4 1. Positive Output Terminal - Must be connected via properlysized cable to the battery or batteries being charged. Cable size is determined by alternator output and length of cable run.
PAGE 12
97-SERIES ALTERNATORS Extra large case 97-Series alternators provide outputs of 160 amps at 12 volts, or 140 amps at 24 volts. 4”ID J-180 saddle mount. Alternators feature isolated ground terminals, external regulation and 16-pole stator output. Models with a BL indicates brushless rotor/ stator combination that reduces alternator noise, and eliminates key wear points. 4 2 1 1. Positive Output Terminal - Must be connected via properly-sized cable to the battery or batteries being charged.
PAGE 13
98-SERIES ALTERNATORS Balmar’s 98-Series alternators are designed to provide outputs of 310 amps at 12 volts, or 220 amps at 24 volts. Mounting is a 4”ID J-180 saddle mount. Alternators in the 98-Series feature isolated ground terminals and a brushless rotor/ stator design that reduces alternator noise, and eliminates key wear points. 4 2 1 1. Positive Output Terminal - Must be connected, via properly-sized cable to the battery or batteries being charged.
PAGE 14
SYSTEM TROUBLESHOOTING Determining the causes of failures in an electrical system is a “step by step” process. Before you begin your search to determine if the failure can be attributed to the alternator or the voltage regulator, we recommend you inspect and clean all system electrical connections. Most charging system problems will be corrected by performing the following steps: 1.
PAGE 15
ALTERNATOR DIAGNOSIS Once the regulator and harness are tested and proven good, disconnect the negative probe of the test lamp from the regulator ground and connect the negative probe to the field terminal of the alternator. Connect the positive probe to the blue (field) wire coming from the regulator. 1. Monitor the test lamp. If the lamp does not illuminate, the alternator may not be completing the connection to ground. Check the ground connections at the alternator to system ground.
PAGE 16
LIMITED PRODUCT WARRANTY BALMAR warrants to the original consumer/purchaser the product is free from any defects in material or workmanship for a period of one year from the date of purchase. If any such defect is discovered within the warranty period, BALMAR will repair or replace the product free of charge, subject to verification of the defect or malfunction upon delivery or shipping prepaid to BALMAR.