Balmar 621 Series Installation And Operation Manual

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
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
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.
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SUP-0207 REV E
3/26/2020