PDS MC 624 H 1
PDS MC 624 H 1
PDS MC 624 H 1
MULTI-STAGE
VOLTAGE REGULATOR
INSTALLATION AND OPERATION MANUAL
Introduction Safety Considerations
The Balmar Max Charge MC-624 is the latest generation of smart, 1. Always disconnect your battery banks
multi-stage Balmar Max Charge voltage regulators. Designed and ensure that switches are “OFF” prior
to provide precise voltage control for Balmar high-output 24-volt to installing your regulator.
alternators and other externally regulated P-type alternators, the 2. Remove loose-fitting clothing or jewelry,
MC-624 features user selectable programs for the following battery which could become entangled in
types: Deep cycle flooded, standard flooded, gel, AGM, spiral your motor or other machinery prior to
wound AGM, and LiFePO4 batteries. In addition, the regulator installing regulator.
features a universal default program that’s safe for most battery 3. Wear ANSI-approved safety eye-wear
types, as well as a program that’s designed for use in vessels and protective gear.
utilizing voltage sensitive halogen equipment.
4. DO NOT attempt to modify the regulator.
In addition to the user selectable preset programs, the MC-624 Modifications could result in damage to
features a wealth of advanced programming modes which make it your charging system, and will void your
possible to tailor charging to a wide variety of environments. warranty.
When used in conjunction with optional MC-TS-A and 5. DO NOT attempt installation if you are
MC-TS-B alternator and battery temperature sensors, the MC-624 tired or fatigued.
features the ability to monitor and respond to a range of ambient
temperature conditions, including reduction or discontinuation 6. Ensure that the engine has cooled
of charging voltages, should a catastrophic over-temperature before initiating installation.
condition occur at the alternator or the batteries. 7. DO NOT attempt regulator installation
while using alcohol or medication that
could impair your judgment or reaction
Table of Contents time.
Introduction 1 Regulator Wire Diagram 10 8. Always use the right tool for the job.
Safety Considerations 1 Regulator Display Modes 11 Improper tool use may damage regulator
Regulator Installation 2 Programming Modes 12 or your vessel, and could result in
Unpacking Box 2 Belt Load Manager 10 personal injury.
Locate/Mount Regulator 2 Dash Lamp Source 10 9. Take time to read the manual. Equipment
Basic Wiring Installation 2 Advanced Programming 11-12 damage and possible injuries may result
LiFePO4 3 Unlock Adv. Programming 11 from an incomplete understanding of
Regulator Terminal Layout 4 Adjust Adv. Programming 11-12 the installation and operation of the
Installation By Wire 5-6 Default Program Settings 12 MC-624 regulator. If you are unfamiliar
Initial Start Up 7 Battery Equalization 12 with marine electrical systems, consult
Regulator Operation 8 Add’l. Regulator Features 13 with a licensed marine electrician.
Programming Flow Chart 9 Troubleshooting 13-15
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.
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.
LFP batteries will readily accept a damaging amount of current. Applying too much charge current
to a LFP battery will, at the very least, permanently damage the battery’s capacity. It is CRITICAL to
ensure that the alternator is not capable of exceeding the maximum continuous charge current rating of
your battery (or batteries). As always, check with 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 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 battery (or batteries)
can handle, you may use the Amp Manager feature on the MC-624 to lower the maximum field drive
output, and thereby lower the maximum alternator output current. See page 10 of your regulator
manual for details and instructions. Be aware that it is not an exact 1:1 correlation between field output
and alternator output, so start with more reduction (lower output) than you think you need and adjust
accordingly.
It is strongly recommended that an alternator temperature sensor (MC-TS-A) be used when charging LFP
batteries. Given the extremely high charge acceptance rate of LFP batteries, the alternator will be driven
to full output for almost all of the charge cycle. This can cause overheating in automotive style alternators
resulting in a significantly shortened lifespan. When equipped with the MC-TS-A temperature sensor,
the MC-624 will help you protect your investment by reducing the field voltage to your alternator by 50%
when over the “AL1” temperature threshold. If you cannot use an MC-TS-A in your application, you should
monitor the alternator’s temperature (measure as close to the loop ends of the stator as possible) and
discontinue charging if the alternator temperature rises above the maximum recommended level. You may
also use the Amp Manager feature on your MC-624 to reduce maximum output until a tolerable alternator
temperature is maintained under all conditions.
Most LFP battery manufacturers specify minimum and maximum charging temperatures to be from
freezing (32°F, 0°C) to around 111°F (44°C). Again, consult with your battery manufacturer for specifics.
When equipped with a MC-TS-B, the MC-624 can disable charging if the battery temperature exceeds
the “B1L” temperature threshold and re-enable charging when the temperature drops below the threshold.
This feature is meant to supplement, not replace, your BMS’s temperature protection features. “B1L”
should be adjusted to be slightly less than BMS’s temperature threshold. Note that the regulator does not
have the capability to prevent charging during low temperatures.
11
3
4 12
+
BANK
Ignition
5 6
7 8
Connector 1
9 10
Co
nn
ect
or
1 2
10A
2
External Regulator D+
3
Plug
11
4 12
Positive Output
Terminal
Installation by Wire 7
CAUTION: Reversing the polarity of the terminal connections on any of the alternator or battery
temperature sensors can result in invalid sensing and potential damage to alternators, regulator
and/or batteries.
R
R
10
35-32
35-61
00 360-4
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2
360-4 ar.ne
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11
3
4 12
Initial Pre-Flight Test And Start-Up
When the regulator is properly 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 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 it’s 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 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 multi-meter, test the following wiring terminals for voltage:
N
N
PTIO
PTIO
N
N
PTIO
PTIO
SOR
SOR
OAT
OAT
LK
D BU
D AB
D AB
SOR
SOR
D FL
D FL
AT
O AT
Y
FLO
TION
TION
O AB
O AB
ELA
O FL
ATE
ATE
ATE
ATE
ATE
MP
P TO
T RA
ORP
ORP
RT D
CUL
CUL
CUL
CUL
CUL
PT
PT
PT
AT
AT
K
RAM
RAM
RAM
RAM
ABS
ABS
CAL
CAL
CAL
CAL
SOF
BUL
CAL
FLO
FLO
STA
1 sec. 60 sec. 18 min. Up to 6 hrs. 18 min. Up to 6 hrs. 18 min. Up to 6 hrs. 18 min. Up to 6 hrs. 18 min. Up to 6 hrs.
+
BANK
Ignition
5 6
7 8
Connector 1
9 10
Co
nn
ect
or
1 2
10A
2
External Regulator D+
3
Plug
11
4 12
Positive Output
Terminal
In addition to the information provided in the basic display shown above, the MC-624 long display provides the
following data. The long display can be accessed at any time during operation by tapping the RED dot with your
magnet.
r2.4 Indicates regulator’s software revision
SLP Indicates, in millivolts, the value used to control voltage compensation for battery temperature.
AP Indicates Amp Manager setting. Followed by maximum allowed field output percentage.
FE Indicates Percentage of field output to the alternator. The higher the percentage, the greater the output
Hr. Indicates overall regulator hours. Followed by hours and then hours in hundreds of hours.
FbA Indicates Field threshold from bulk to absorption. Factory set at 77%.
FFL Indicates field threshold from float to absorption. Factory set at 77%. Adjust in advanced programming mode.
E Indicates system advisory codes. Individually numbered codes are defined below.
The following advisory codes can be used to determine possible system errors or to identify specific operational
modes. Note that E codes are cumulative and will be held in memory until cleared. Codes can be cleared by
entering dSP and letting it save. Display settings DO NOT need to be changed. See basic programming for more
info.
E10 BATTERY #1 SENSOR E15 ALTERNATOR #1 TEMP. E41 FIELD VOLTAGE TOO HIGH
CABLE SHORTED SENSOR CABLE OPEN OR NOT
FOUND E42 STATOR VOLTAGE TOO
E11 BATTERY #1 TEMP. SENSOR
CABLE OPEN OR NOT FOUND E20 BATTERY #1 TOO HOT OVER HIGH
55°C. FACTORY DEFAULT E51 SMALL ENGINE MODE IS IN
E12 BATTERY #2 TEMP. SENSOR
CABLE SHORTED E21 BATTERY #2 TOO HOT. OVER OPERATION
55°C. FACTORY DEFAULT E52 BELT LOAD MANAGER IS IN
E13 BATTERY #2 TEMP. SENSOR
CABLE OPEN OR NOT FOUND E22 ALTERNATOR TOO HOT. OPERATION
OVER 107°C
E14 ALTERNATOR #1 TEMP.
SENSOR CABLE SHORTED E24 VOLTAGE REGULATOR TOO
HOT. OVER 90°C
Basic Programming
Programming For Battery Type
The MC-624 features selectable programs for SEVEN battery technologies. Programming can be done whenever the
regulator is active. System voltage must be greater than 25.0V for programming changes to be saved.
To adjust the regulator for your battery type:
1. Turn on the regulator. If the regulator’s BROWN ignition wire is connected to an oil pressure switch, it may be
necessary to start the engine to activate the regulator.
2. Once the regulator is on and the display is scrolling, TOUCH / HOLD the magnetic end of the programming screw-
driver to the RED dot on the regulator as described above.
3. Continue to hold the magnet to the RED dot. The letters PRO will appear on the LED.
4. Continue to hold the magnet to the RED dot. The display will scroll through the seven available preset battery
programs. The battery programs are signified by one of the program numbers shown below.
5. When the desired battery code is displayed, RELEASE the magnet from the RED dot.
6. The regulator will indicate the Pro code once the reed switch is released, followed by the SAV code to indicate that
the program change has been saved.
REVERSING DIRECTION OF SCROLL: The regulator display from P01 to P07 and will then stop. To reverse
the direction of scroll, remove the magnet from the dot until the PRO code is displayed, then re-activate
and hold. The display will then scroll downward until the desired code is shown.
Pro INDICATES ENTRY INTO BASIC P03 INDICATES PROGRAM FOR P06 INDICATES STANDARD
PROGRAMMING MODE SEALED GEL BATTERIES (GEL) FLOODED PROGRAM (FSB)
P01 INDICATES UNIVERSAL FACTORY P04 INDICATES ABSORBED GLASS P07 INDICATES PROGRAM
PROGRAM (FACTORY DEFAULT) MAT BATTERIES (AGL) FOR LiFePO4
P02 INDICATES DEEP CYCLE FLOODED P05 INDICATES PROGRAM FOR SAV INDICATES PROGRAM
BATTERY PROGRAM (FDC) OPTIMA BATTERIES (OPS) CHANGE IS SAVED
NOTE: A CHART DESCRIBING VOLTAGE, TIME AND ALARM SETTINGS FOR EACH SELECTABLE BATTERY
PROGRAM IS AVAILABLE ON PAGE 14 IN THIS MANUAL.
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)
12
Advanced Programming
Accessing The Advanced Programming Mode
The MC-624 provides a broad range of advanced user adjustments in its Advanced Programming mode. The Ad-
vanced Programming mode can be accessed at any time via the following steps:
1. With the regulator activated, TOUCH / HOLD the magnet to the RED dot on the regulator’s epoxy potting.
2. The regulator will cycle to PRO.
3. Remove the magnet from the switch when the PRO code is displayed.
4. The PrA code will be displayed, indicating entry into the Advanced Programming mode, followed by codes for the
individual Advanced Programming adjustment codes as described below.
5. Re-activate and hold when the desired Advanced Programming adjustment mode is indicated.
Pro INDICATES ACTIVATION OF MAGNETIC REED SWITCH / ENTRY INTO PROGRAMMING MODE. RELEASE
MAGNET FROM SWITCH AS SOON AS PRO CODE IS INDICATED.
PrA INDICATES ENTRY INTO ADVANCED PROGRAMMING MODE. PRA CODE WILL BE FOLLOWED BY INDIVIDUAL
PROGRAMMING MODES AS INDICATED BY CODES BELOW.
BAT. TEMP. COMPENSATION 6.0mV/°C 6.0mV/°C 5.0mV/°C 3.8mV/°C 5.0mV/°C 6.0mV/°C 0.0mV/°C
System Troubleshooting
Regulator Troubleshooting
The majority of charging difficulties can be attributed to damage, corrosion or wear at wiring, fusing or wiring
connections. Please note: the regulator will not produce field output if the system voltage is below 22V. Please
ensure that voltage is above 22V when testing the system for proper operation. Before attempting to
troubleshoot alternator or regulator issues, be sure to address the following:
1. Remove and clean all charging system electrical connections (positive and negative). Check the voltage
regulator’s harness for continuity. Wires and terminals can and will become corroded, and need to be cleaned or
replaced. Ensure that the regulator’s ground wires are provided with a clean connection to system ground.
2. Inspect and replace 10A fuse in the regulator wiring harness if fuses appear to be damaged or corroded. Ensure
that the fuse holder is also free of corrosion.
3. Charge all batteries to their proper fully charged state, and determine if they are serviceable. If your batteries
are flooded-type, use your hydrometer to determine their condition.
4. Check and tighten alternator belt. If the belt show signs of wear or damage, replace it. Always replace existing
belts with the finest quality replacements available.
If batteries and wiring are in suitable condition, use the tests on the following page to determine if charging prob-
lems are a result of a faulty alternator or regulator. These tests provide an opportunity to isolate the alternator, regu-
lator and wiring harness in order to determine the problem source. In order to perform these tests, you will need an
independent DC meter (preferably a digital type). In an emergency, a 12V or 24V light bulb or test light can be used
to help determine if power or working grounds exist. An amp meter and a battery hydrometer with a thermometer
are also helpful diagnostic tools.
Alternator Testing
TEST #1- The following test is used to isolate the alternator and determine if the failure is a result of the alternator.
Once again, testing at either the alternator or regulator is only effective if the wiring, fusing and batteries have been
determined to be in correct working order. The alternator and regulator can be tested for function by determining if a
magnetic field exists at the alternator’s pulley shaft or rear bearing. To test:
1. With the ignition in the OFF position, place the tip of a non-magnetic steel screwdriver near the nut on the
pulley shaft or near the rear bearing of the alternator. There should be no evidence of a magnetic field pulling
the screwdriver toward the alternator. (A slight amount of magnetism may be present, due to residual voltage
in the alternator.)
2. Engage the ignition, without starting the engine, to activate the voltage regulator. If an oil pressure switch is
used, a jumper between the RED and BROWN wires in the Ford-style plug will activate the regulator.
Warranty Resolution
If Balmar authorizes a product to be returned to Balmar or an authorized service provider, Balmar will repair the product or replace it without
charge with a functionally equivalent replacement product. Balmar may replace the product with a product that was previously in service
or repaired, but re-tested to meet Balmar specifications. Balmar will pay to ship the replacement product to the purchaser. By sending the
product for replacement, ownership of the original product will be transferred to Balmar. Labor charges at the consumer’s site are not covered
under this Warranty. Balmar warrants that repaired or replaced products shall be covered under the Balmar Warranty for the remainder of the
original product warranty, or 90 days, whichever is greater.
Applicable Laws
Balmar’s Warranty is governed by the laws of the State of Alabama, USA. The Balmar Warranty provides the purchaser specific legal rights,
and you may also have other rights that vary from state to state. Balmar’s Warranty does not affect any additional rights consumers have
under laws in their jurisdictions governing the sale of consumer goods, including, without limitation, national laws implementing EC Directive
44/99/EC. Some states do not allow the exclusion of limitation of incidental or consequential damages, so the limitation or exclusions of
Balmar’s Warranty may not apply in certain jurisdictions.
Once Balmar receives the product, we will test the product to determine if the problem is due to a defect in the product. If, at the sole
discretion of Balmar, the problem is determined to be a manufacturer defect, Balmar will repair the product or send a new product to replace
the defective product.
Balmar will not provide Warranty coverage unless Warranty claims are made in compliance with all the terms listed here, and the specified
return procedures are followed.
For more information, contact Balmar Customer Service or Technical Support at +1(360) 435-6100 or visit the Balmar website at
www.balmar.net. Balmar LLC believes all information herein to be factual and accurate, yet maintains no liability for factual or typographic
error. In addition, Balmar retains the right to revise or update products without notification. Visit the Balmar website for product updates
or bulletins and may apply to your alternator or voltage regulator. No part of this document may be reproduced without express written
permission of Balmar LLC © Copyright 2017.
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, delete, supplement, or otherwise amend at any time the information
and policies contained in this guide.
For the most recent information about Balmar’s products, policies and
instructions please visit, www.balmar.net.