Balmar XT-DF Series Installation And Operation Manual
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Balmar XT-DF Series Installation And Operation Manual

Alternator
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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, LiFePO
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.
CONTENTS
INTRODUCTION ................................................1
SAFETY CONSIDERATIONS ..............................1
ALTERNATOR MOUNTING STYLES ..................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
BATTERY SWITCHES ........................................5
BATTERY COMBINERS/SOLENOIDS .................5
BATTERY ISOLATOR .........................................5
DIGITAL DUO CHARGE ......................................6
TWIN ENGINE ISSUES ......................................7
CENTERFIELDER ...............................................7
INSTALLATIONS BY ALTERNATOR ...................8
6-SERIES ALTERNATORS ...............................8-9
XT-SERIES ALTERNATORS..............................10
AT-SERIES ALTERNATORS..............................13
94 & 94LY-SERIES ALTERNATORS .................13
95-SERIES ALTERNATORS ..............................14
97-SERIES ALTERNATORS ..............................14
97EHD-SERIES ALTERNATORS .......................14
98-SERIES ALTERNATORS ..............................15
SYSTEM TROUBLESHOOTING ...................16-18
WARRANTY .....................................................20
, Optima and other marine battery technologies. When
4

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 fitting 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 sufficiently before begin-
ning installation.
5. DO NOT install your high-output alternator without ensuring
that system wiring is sufficient 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 suffi-
ciently experienced with marine electrical systems, we recom-
mend a qualified electrician be used for installation.
Page
1
SUP-0207 REV E
3/26/2020

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Summary of Contents for Balmar XT-DF Series

  • Page 1: Table Of Contents

    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, LiFePO , Optima and other marine battery technologies.

  • Page 2: Alternator Mounting Styles

    Please note that the internal regulator must be disabled when an external regulator is being used. 6. All Balmar alternators except Case-Ground versions of the XT-Series are equipped with isolated grounding ter- minals. Isolated ground alternator installations MUST include a dedicated cable connecting the alternator ground terminal to system ground.

  • Page 3: Sizing Battery Cables

    (measured across the back of the belt) for our 70-amp (12-volt) alternators. Minimum belt width for 100-amp alter- nators is 1/2". Any 12-volt alternator larger than 100-amps or 24-volt Balmar alternator will require dual belts or a flat, multi-groove belt for optimal performance, as well as acceptable belt life.

  • Page 4: Pulleys

    200 degrees (F). If your system is operating with a Balmar multi-stage voltage regulator with optional Alternator Tem- perature Sensor (MC-TS-A), the regulator will automatically reduce field output if temperatures exceed set safe working limits.

  • Page 5: Multiple Bank Charging Options

    -- or a starting battery, along with multiple banks for house loads, inverter loads, windlass or thruster. Many methods of multi-bank charge control are available, ranging from manual switches to products like Balmar’s Digital Duo Charge (which automatically provides charging current to the starting battery whenever charging volt- age is present at the house battery).

  • Page 6: Digital Duo Charge

    This type of system is commonly used to supply a large house bank, with a Duo Charge unit providing charging current to the starting battery. For more information on the MC-612-DUAL, visit the Balmar website at www.balmar.net. •...

  • Page 7: Twin Engine Issues

    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 combin- ers. Combining the output from two alternators on two engines will require the use of Balmar’s Centerfielder II (described below).

  • Page 8: Installations By Alternator

    INSTALLATIONS 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, Alternators in the 6-Series family feature iso-...
  • Page 9 USING THE SMARTREADY ® INTERNAL VOLTAGE REGULATOR The 6-Series and XT-Series alternators are 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 ®...

  • Page 10: Xt-Series Alternators

    XT-SERIES ALTERNATORS – 170A XT alternators are Smart Ready and feature 16 stator poles ® XT-Series alternators are available in three mounting configurations: • SF models: 1" or 2" single foot mount Smart Ready ® • DF models: 3.15” ID saddle mount Smart Ready ®...
  • Page 11 Single-foot and Vortec mount versions Case Ground: 1. Positive Output Terminal - Must be connected via properly-sized cable to the battery or batteries being charged. Cable size is determined by alterna- tor output and length of cable run. See Page 3 for wiring size chart. 2.
  • Page 12 Single-foot and Vortec mount versions Isolated Ground: Positive Output Terminal - Must be connected via properly-sized cable to the battery or batteries being charged. Cable size is determined by alternator output and length of cable run. See Page 3 for wiring size chart. 2.

  • Page 13: At-Series Alternators

    AT-SERIES ALTERNATORS – 220A Advanced Technology (AT-Series) alternators are available in three mounting con- figurations: • SF models: 2" single foot. • DF models: 3.15” ID saddle mount. • DF4 models: 4” (J-180) saddle mount. • AT-Series alternators are isolated ground, externally regulated, and feature 16 stator poles.

  • Page 14: 95-Series Alternators

    95-SERIES ALTERNATORS Large case 95-Series alternators are designed to provide outputs of 165 or 210 amps at 12 volts, or 140 amps at 24 volts. Mounting is a 4”ID J-180 saddle-style mount. Alternators in the 95-Series feature iso- lated ground terminals, external regulation and 12-pole stator output. 1.

  • Page 15: 98-Series Alternators

    98-SERIES ALTERNATORS Balmar’s 98-Series alternators are designed to provide out- puts of 310 amps at 12 volts, or 220 amps at 24 volts. Mount- ing is a 4”ID J-180 saddle mount. Alternators in the 98-Se- ries feature isolated ground terminals and a brushless rotor/ stator design that reduces alternator noise, and eliminates key wear points.

  • Page 16: System Troubleshooting

    System Troubleshooting Regulator Troubleshooting The majority of charging difficulties can be attributed to damage, corrosion or wear at wiring, fusing or wiring connections. Before attempting to troubleshoot alternator or regulator issues, be sure to address the following: Remove and clean all charging system electrical connections (positive and negative). Check the voltage regulator’s harness for continuity.
  • Page 17 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 alternator: Clip a jumper wire to the positive post of the alternator, or on the battery side of the isolator (if an isolator is in use).
  • Page 18 Do not allow extended unregulated charging to occur without carefully monitoring voltage levels. If the alternator fails to generate voltage during field testing, a malfunction of the alternator is likely. Contact your local alternator repair shop or Balmar’s technical service staff for recommendations. SMART READY REGULATOR TEST ®...
  • Page 19 NOTES Page 19...

  • Page 20: Warranty

    Attention: Warranty Returns RMA# 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.

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