High Output Alternators

Transcription

1 High Output Alternators & Regulators GENERATE High Output Alternators Tel:

2 GENERATE High Output Alternators & Regulators Balmar Leaders In High Output Alternators With increasing electrical demand on-board yachts and specialist vehicles, a high output alternator ensures that batteries continue to charge quickly and fully. Yacht engines and vehicles are supplied with standard automotive alternators that are too small to cope with larger battery bank sizes and increased electrical load. What's more, the engine needs to be run at high speed to gain maximum alternator output. High output alternators are designed to produce useable output at lower RPM while an optional smart regular will ensure it delivers a 4 stage charge to the battery bank. Why Any Alternator Just Won t Do Conventional alternators (even just bigger output ones) are not designed to deal with continuous heavy duty loads, large capacity and specialist battery banks. Produced for the general automotive market, these units are designed for normal road conditions, relatively high engine speeds and low loadings (lights, wipers and fan). In marine/off road/side of road applications, engines spend lengthy periods at idle or low RPM. This is not fast enough to switch on some alternators, let alone provide meaningful charging output. Larger (and specialist chemistry) battery banks need high current to recover from deep discharges and special charging regimes to achieve 100% recharge. Ordinary alternators have a fixed voltage output that recovers batteries to only around 80% of their true capacity. Heat is the biggest cause of alternator failure. Under the bonnets/hoods of cars, vans and trucks, a continuous and large air-flow runs around the alternator. Engine rooms on boats have virtually no air-flow. Balmar alternators are engineered with numerous passive thermal management features such as dual fans, high temperature rated diodes and coatings. Active temperature monitoring and control comes with certain Balmar regulators to further mitigate overheating problems. Off-road vehicles and boats operate in harsh environments. Damp conditions, salt-spray and vehicle wading leads to serious corrosion problems. Balmar alternators feature internal coatings, stainless hardware and sealed electronics The graph shows the Balmar 60 Series 70A 12V model s output vs a conventional 70A automotive unit (Delco Remy 10si Series). The Balmar provides around 60 amps at 1500 RPM bear in mind that most engines have a 3:1 pulley ratio (meaning that the alternator spins three times as fast as the engine) eg 60A at engine idle! Economic Benefits Balmar alternators pay for themselves. As the graph above explains, significantly higher charging current is provided at lower RPM. This results in quicker charging time (less time spent running the engine to charge batteries), fuel and engine wear savings. Batteries that are not correctly charged will fail prematurely Balmar alternators save engine running cost and extend battery life. Applications Balmar alternators are primarily designed for marine use. However, Merlin have sold Balmar alternators into specialist vehicles, DC generator and industrial applications over many years where low RPM and high output is required. 6

3 High Output Alternators & Regulators GENERATE Choosing Your Alternator There are 4 factors to consider when choosing a high output alternator. Current Output Choosing the right sized alternator for your battery bank is important. A general rule of thumb is a 4:1 ratio - eg a 400Ah battery bank would need a 100A alternator. However, if using more exotic battery types (such as our Fullriver AGM or Li-Ion cells), you could drop this ratio to 1:2 (or even 1:1!) for very rapid recharge times (check with the battery manufacturer/supplier first!). Application (low RPM, Commercial & Continuous Duty Use) Our alternators vary considerably in their features, construction and cost. The range is split into different sections according to their ability to deliver higher current at low RPM and overall ruggedness. Fitting Retrofitting alternators can be an involved job. While some of our units are designed to be direct "bolt for bolt" replacement for existing alternators, be prepared to make bracket modifications and/or insert spacers/washers to make the unit fit. If you are not capable of this, employ a good engineer. Merlin Equipment supplies detailed dimensioned drawings of all Balmar Alternators and will provide specifying help. However, It is your responsibility to ensure that you have ordered the correct alternator for your engine (and checked that the alternator will fit in all dimensions). Since Balmar alternators are built to order, a re-stocking fee does apply if the alternator doesn t fit. We strongly recommend fully discussing your requirements with a qualified Merlin engineer - telephone Fitting Conventions: Virtually all alternators use one of four fitting configurations. These are industry standard. Single Foot 1" Mount Single Foot 2" Mount Dual Foot. Smaller engines have a 3.15" spacing between the mounting lugs. Larger engines often have a 4" spacing. Regulation Apart from the 6 series (which has a built in regulator), all Balmar alternators require a regulator. Fixed voltage output, single stage and advanced multi-stage regulators are available. All external regulators will work with all Balmar alternators. 6 Series: Small Case, High Output. Designed to be a direct replacement for OEM alternators. Supplied with internal single stage regulator. 6 Series units can be upgraded to 4 stage smart charging units by simply plugging in a Balmar ARS or Maxcharge Regulator. Perfect for recreational boats and smaller commercial vehicles amps 12/24V. AT Series: 9X Series: Advanced Technology. AT units provide the most power output possible from a small case alternator. Perfect for vehicles or boats where larger case alternators cannot be fitted yet high charge current is required. Externally regulated must be used with Maxcharge Alternator Regulator amps 12V. Large Case Power Handlers. Continuous duty for professional marine and large system users. Designed to operate for lengthy periods of time; Day in, day out. External Regulation amps 12/24V. 7

4 GENERATE High Output Alternators & Regulators Series Features s 6 Series AT Series Replaces existing European Style Alternators Built in Internal Regulator Plug & Play compatibility with Balmar Smart Regulators Twin Internal Fans D+ Terminal, Tacho Output & Isolated Ground Multi-fit flange for easy adjustment Direct bolt for bolt replacement for most standard engine alternators 50+ Amps at engine idle, High output at low RPM 60-Series generally fit Yanmar Engines 621 Series generally fit Volvo Engines Advanced Alternator windings produce extremely high current from a small case alternator Ideal for small engines & very large battery banks Extremely high output at low RPM Twin Internal Fans Suitable for charging Lead/Acid, Gel, AGM and Lithium Ion Cells Available in single or dual foot mounting Must be used with Maxcharge External Regulator Isolated Ground Lead time typically 28 days Other models available by by special order - see - see data Other models available by by special order - see - see datas Merlin Balmar Voltage Current SR-IG 12V 12V 70A 70A SR-IG 12V 12V 100A 100A SR-IG 12V 12V 150A 150A SR-IG 24V 24V 70A 70A SR-IG 12V 12V 70A 70A SR-IG 12V 12V 100A 100A SR-IG 12V 12V 150A 150A SR-IG 24V 24V 70A 70A Merlin Balmar Voltage Current M AT-SF-165-SR-IG 12V 12V 165A 165A AT-DF-165-SR-IG 12V 12V 165A 165A AT-SF-200-SR-IG 12V 12V 200A 200A AT-DF-165-SR-IG 12V 12V 200A 200A 9x Series Large & Extra Large Case Alternators for heavy duty, continuous charging applications. 50+ amps at idle engine speed Super Heavy Duty construction Most feature brushless design for reduction in EMC emissions and servicing External Regulation Only (Can be used with any Balmar External Regulator) Each features hand wound and balanced rotors, high speed bearings, high temperature diode packs and internal/external coatings to resist corrosion (even in the marine environment) Isolated Ground design All 9x Series units are built to order and available generally within 28 days from date of order. Merlin Balmar Voltage Current IG 12V 12V 165A 165A IG 12V 12V 210A 210A IG 24V 24V 140A 140A LY IG* 12V 12V 165A 165A LY IG* 12V 12V 210A 210A LY IG* 24V 24V 140A 140A IG 12V 12V 165A 165A IG 12V 12V 210A 210A IG 24V 24V 140A 140A IG 12V 12V 165A 165A IG 24V 24V 140A 140A EHD V 12V 185A 185A EHD V 12V 265A 265A EHD V 24V 190A 190A IG-BL 12V 12V 310A 310A IG-BL 24V 24V 220A 220A * Supplied with hardware for for Yanmar engines (te 8

5 High Output Alternators & Regulators GENERATE Further Info ent Mounting Supplied Regulation Pulley Pulley (Belt (Belt Size) Size) A1" or 1" 2" or Single 2" Single Mounting Foot Foot Single Single 1/2" 1/2" Built Built in single stage, Optional External Regulator 1" A or 1" 2" or Single 2" Single Mounting Foot Foot Single Single 1/2" 1/2" Built Built in single stage, Optional External Regulator 1" A or 1" 2" or Single 2" Single Mounting Foot FootDual Dual 1/2" 1/2" Built Built in single stage, Optional External Regulator A1" or 1" 2" or Single 2" Single Mounting Foot FootDual Dual 1/2" 1/2" Built Built in single stage, Optional External Regulator ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Single Single 1/2" 1/2" Built Built in single stage, Optional External Regulator ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Single Single 1/2" 1/2" Built Built in single stage, Optional External Regulator ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Dual Dual 1/2" 1/2" Built Built in single stage, Optional External Regulator ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Dual Dual 1/2" 1/2" Built Built in single stage, Optional External Regulator datasheets for details for details Other models available by special order - see datasheets for details Scan QR Code for direct link to Balmar 6 Series Data Sheet or check on line at Mounting Supplied Regulation Pulley Pulley (Belt (Belt Size) Size) 1" A or 1" 2" or Single 2" Single Mounting Foot Foot K6-2" K6-2" Poly Poly V V Use Use Maxcharge Regulator Only A Twin Twin Mounting Mounting Foot Foot (3.15") (3.15") K6-2" K6-2" Poly Poly V V Use Use Maxcharge Regulator Only 1" A or 1" 2" or Single 2" Single Mounting Foot Foot K6-2" K6-2" Poly Poly V V Use Use Maxcharge Regulator Only A Twin Twin Mounting Mounting Foot Foot (3.15") (3.15") K6-2" K6-2" Poly Poly V V Use Use Maxcharge Regulator Only datasheets for details for details Other models available by special order - see datasheets for details Scan QR Code for direct link to AT Series Data Sheet or check on line at ent Mounting Supplied Regulation Pulley Pulley (Belt (Belt Size) Size) 5A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 5ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0ATwin Twin Mounting Mounting Foot Foot (3.15") (3.15") Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 5A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A 2" Single 2" Single Foot Foot Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 5A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 5A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 5A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator 0A J180 J180 Saddle Saddle Mount Mount Dual Dual 1/2" 1/2" ERS. ERS. BRS, BRS, ARS ARS or or Maxcharge Regulator s (tensioning arm arm p/n: p/n: ) * Supplied with hardware for Yanmar engines (tensioning arm p/n: ) Scan QR Code for direct link to Balmar 9x Series Data Sheet or check on line at 9

6 GENERATE High Output Alternators & Regulators Regulation The Key To Efficient Charging Selecting the right regulator is critical to ensure that your charging system works at maximum efficiency. With the exception of the Balmar 6 series alternators, all Balmar Alternators require an external regulator. The 6 Series alternator has a basic, single stage regulator built in this may be upgraded by simply plugging in an external Balmar regulator. Single or Multistage? Single Stage regulators clamp the alternator output voltage at a set level (adjustable on certain units). It is the most basic form of regulation (similar to that of a standard automotive alternator). May be useful for when the alternator is used as a DC generator or when recharging times are too short to benefit from multistage charging. Multistage regulators provide Bulk, Absorption & Float charging. This improves recharge time by around 30% and ensures fuller, safer charging. Multistage charging is essential for certain battery types. Balmar multistage regulators add further features that turn your alternator into a true smart charging device. For full explanation of multistage charging, see page 11. ERS-P Regulator Single Stage regulator IP66 Sealed for wet & ignition protected environments Compatible with all 12V Balmar Alternators Ideal as a spare get you home regulator Voltage (Nominal / Output) 12V / 14.1 VDC Dimensions (HxWxL) mm (inch) 58x33x18 (2.3x1.3x0.7) Weight (lbs) 450g (1) BRS Regulator Single Stage Regulator Output Voltage Adjustment Fault, Charging & Charged LED Indicators Supplied with Harness Fully sealed for wet and ignition protected environments Suitable for all Balmar Alternators The Balmar BRS Regulator is a single stage regulator ideal for applications where multistage charging is not desired. The adjustable output voltage allows you to set the most suitable charge voltage for your on-board batteries and split charging system. Available for 12 and 24V Balmar Alternators Voltage (Nominal / Output) 12V / adjustable 24V /adjustable Dimensions (HxWxL) mm (inch) 121x81x38 (4.8x3.2x1.5) 116x76x19 (4.6x3.0x0.75) Weight (lbs) 680g (1.5) 680g (1.5) 10

7 High Output Alternators & Regulators GENERATE ARS-5 & Maxcharge Regulators Advanced Multistage Regulators Suitable for all Balmar Alternators Soft ramp up alternator belt protection Programmable for various battery types Alternator & Battery temperature sensing 50% output mode for when engine power is needed for urgent manoeuvring Digital display Fault code analysis ARS-5 and Maxcharge regulators add advanced multistage charging to your Balmar Alternator. Both provide significant improvements in battery charging performance the ARS being designed for smaller installations while the Maxcharge adds additional features required for the larger Balmar alternators and bigger charging systems. Multistage Charging ARS & Maxcharge turn your alternator into a 4 stage charging device. This ensures total, fast and safe recharge of high capacity battery banks. Reduces overall charge time by up to 30%. This style of charging perfectly suits AGM and Gel batteries and helps prevent sulphation and stratification. The 4 stage output allows the alternator to act as a power supply and keep up with the high power demands of DC powered airconditioning and DC/AC power inverters. Smart Sensing Both units have the ability to interact with multiple sensors to adapt charging characteristics. These include: Remote Voltage Sensor by sensing alternator output at the batteries, the regulator is able to increase output voltage to overcome excessive voltage drop across inefficient split chargers, lengthy cable runs, battery switches, fuses etc. Alternator Temperature Sensor available as an option, this allows the regulator to reduce charging output in the event of the alternator overheating (likely where engine room ventilation is inadequate or when charging very high capacity AGM or Lithium Ion batteries). Battery Temperature Sensor available as an option, the Battery Temperature Sensor allows the regulator to adjust charging voltage according to ambient temperature this prevents overcharged batteries in summer and undercharged ones in winter. Soft Ramp Big alternators place alternator belts under increased strain. This can lead to increased belt wear, slippage and in extreme cases belt breakage. ARS & Maxcharge regulators incorporate a user-programmable soft-ramp feature that allows the engine and belts to warm up and gradually increases power to reduce or completely eliminate belt issues. Both units also have the ability to instantly switch off or reduce alternator output to 50% - this is an important feature for engines which are slightly underpowered and allows you to divert all available horsepower to manoeuvring instead of charging batteries. Programmability Both units are supplied with numerous battery programmes to suit most marine & automotive batteries including lead/ acid, sealed lead/acid, Gel, Optima and AGM. Programmes and fault code analysis is made easy using the LED display fitted to the front of the unit. Maxcharge also allows you to custom build your own charge profile. 11

8 GENERATE High Output Alternators & Regulators MaxCharge Dual Maxcharge Dual is the first regulator designed to control two alternators (on the same engine at the same time) and charge a single, large battery bank; Both alternators then work together as a single large charging source. Multistage Regulators Specifications ARS-5 MaxCharge MaxCharge Dual Recommended Max Alternator Size 150A 12V/ 70A 24V 550A 12V / 220A 24V 550A 12V / 220A 24V Multistage Charge Output Yes Yes Yes Lead/Acid Battery Program Yes Yes Yes Sealed Lead/Acid Battery Program Yes Yes Yes Gel Battery Program Yes Yes Yes AGM Battery Program Yes Yes Yes Optima Battery Program Yes Yes Yes of Battery Programmes Alternator Temperature Sensing Yes Yes Yes x2 Battery Temperature Sensing Yes x 1 Yes x2 Yes x2 Maximum field output current 7A 15A 15A Alphanumeric LED Display Yes Yes Yes IP66 Rated / Ignition Protected Yes Yes Yes Soft Ramp Up Yes Yes Yes Fault Code Display Yes Yes Yes Harness Suppled (1.4m - 54") Yes Yes Yes x2 Halogen Bulb Protection Program Yes Yes Customisable Charge Program Yes Yes Adjustable charge parameters Yes Yes Suitable for controlling twin alternators No Yes Suitable for Lithium Ion Charging Yes Yes Programmable Soft Ramp Up Yes Yes Fault Code Memory Yes Yes Centrefielder Compatible Yes Yes AT Series Alternator Compatible Yes Yes Dimensions (LxWxH) mm (Inches) 122x82x38 (4.8x3.2x1.5") Weight (lbs) 0.45g (1lb) 0.45g (1lb) 0.45g (1lb) Merlin - 12V Models Merlin - 24V Models Not Available Alternator Temperature Sensor #: Battery Temperature Sensor #: Recommended Applications: 12

9 High Output Alternators & Regulators GENERATE Special Order Alternator Packages Balmar Alternator/Regulator packages represent superb value for money each providing significant savings over buying each component individually. Lead time approximately 28 days. 6 Series Alternator Packages 6 Series Alternator ARS or Maxcharge Regulator Alternator Temperature Sensor Battery Temperature Sensor Wiring Harnesses Fitting Kit Full Manual Delivery typically 28 days 621 Series models generally fit Volvo engines. 60 Series models generally fit Yanmar engines. Please check fitting before purchase. Alternator ARS-5 Regulator Maxcharge Regulator 621 Series 70A 12V Series 100A 12V Series 150A 12V Series 70A 24V Not Available Series 70A 12V Series 100A 12V Series 150A 12V Series 70A 24V Not Available AT Series Alternator Packages AT Series Alternator Maxcharge Regulator Alternator Temperature Sensor Battery Temperature Sensor Wiring Harnesses Fitting Kit Full Manual Delivery typically 28 days Alternator Maxcharge Regulator AT Single Foot 165A 12V AT Single Foot 200A 12V AT Twin Foot 165A 12V AT Twin Foot 200A 12V AT 4" Saddle Mount 200A 12V Single Foot models generally fit Volvo engines. Twin Foot models generally fit Yanmar engines. Please check fitting before purchase. Centerfielder Centerfielder is a regulator balancing device that allows alternators on two different engines to synchronise and charge a single battery bank. Perfect for twin engine power boats and catamarans where it is desirable to have both alternators directly charge the auxiliary batteries for faster charging. Also provides isolation between each alternator in case only one engine is running. Prevents regulators fighting and the losing regulator shutting down. Compatible only with Maxcharge 12 or 24V regulators. #: Installation Example: Maxcharge Port Alternator Engine Batteries not shown Centerfielder Maxcharge Stbd Alternator Auxiliary Battery 13

10 Your Your Authorized Dealer: Merlin Power Systems Europe: Unit 3-4, Cabot Business Village Holyrood Close Poole, Dorset BH17 7BA United Kingdom Telephone: +44 (0) Fax: +44 (0) North America: West Montauk Highway Hampton Bays New York, NY11946 United States of America Telephone: +1 (631) Fax: +1 (631)