Balmar alternator/regulator problems

[[2574]]

I've a new Balmar 70A alternator which is regulated by a Balmar ARS5 regulator. Fitted last winter. This summer I noticed that our engine (Yanmar75hp), whilst running at low rpm, was constantly changing it's tone, I thought it was fuel starvation or some other mechanical problem as the change in engne sound was positively noticeable. I checked filters and suchlike. Then I happened to notice that the output from the alternator was fluctuating between about 15A and 50A every second or so. The change in load from the alternator was sufficient to change the tone of the engine.

I've been in contact with Balmar and so far they've not been able to provide any guidance as to what the issue might be. It's been suggested that I increase the float voltage but I don't fancy that as it'll cook the new 750AH AGM battery bank. So I'm at a bit of a loss and on the point of swapping out to a different alternator, perhaps a Wakespeed, undecided at present.

If anyone has any experience of anything similar and can provide details of if/how it was resolved I'd be very grateful to read the details.

If you can bear it here is a dropbox link to a video showing the fluctuation of the amperage/voltage as seen on my Victron power monitor. 20220923_151253.mp4

 

[rotrax]

I should think it was! When I did a bit of rolling road dynomometer testing a Jaguar car with all the electrical devices pulling lots of amps would lose over 4 BHP.

Unlikely to be an alternator problem, but a regulator one.

I would disconect the field winding and supply a small current through a low wattage bulb. If the output then remains steady you will have isolated the issue to the regulator.

 

[Poey50]

So I'm at a bit of a loss and on the point of swapping out to a different alternator, perhaps a Wakespeed, undecided at present.

Do you mean swapping to a different external regulator? Can you get your ARS-5 sent off to be tested ?

 

[[2574]]

Do you mean swapping to a different external regulator? Can you get your ARS-5 sent off to be tested ?

Well yes I was thinking of a different regulator. Maybe I could get the ARS5 tested but I guess it would need to be shipped back to the US. The UK supplier has been very helpful in trying to sort this out, I could maybe try a replacement unit from him. I'm thinking that I should do some local testing to see if I can identify what might be causing the regulator to do this - any other relays in the circuitry that might be opening or closing in response to the voltages and thereby working against the ARS5 maybe?

 

[Poey50]

Well yes I was thinking of a different regulator. Maybe I could get the ARS5 tested but I guess it would need to be shipped back to the US. The UK supplier has been very helpful in trying to sort this out, I could maybe try a replacement unit from him. I'm thinking that I should do some local testing to see if I can identify what might be causing the regulator to do this - any other relays in the circuitry that might be opening or closing in response to the voltages and thereby working against the ARS5 maybe?

What settings have you used? Did you use the advanced programming?

 

[[2574]]

What settings have you used? Did you use the advanced programming?

Yes, amended one parameter under Balmar's guidance. Other than that the advanced parameters are all default. (Battery type etc isn't in the advanced section)

 

[Poey50]

Yes, amended one parameter under Balmar's guidance. Other than that the advanced parameters are all default. (Battery type etc isn't in the advanced section)

Do you know the settings?

 

[Poecheng]

I have a spare regulator, think it is an ARS -4, (I am sure it is not a 5) but it should be sufficient to check. Let me know if of any use and I can pop it in the post for you to test.

 

[[2574]]

Do you know the settings?

Yes, in the Balmar manual (there are quite a few as I'm sure you aree aware!)

 

[[2574]]

I have a spare regulator, think it is an ARS -4, (I am sure it is not a 5) but it should be sufficient to check. Let me know if of any use and I can pop it in the post for you to test.

Really very kind, thank you. I'm going to test some local stuff first. For example the output from the alternator goes to a Victron Argofet for dividing between three battery banks. I am wondering if the intricacies of that device might cause the oscillation of charge in to the house bank.

Argofet Battery Isolators - Victron Energy

 

[Boater Sam]

I have experienced this with an alternator regulator, not a Balmar, and it was due to a component tolerance in the regulator.

First I would try disconnecting one battery bank at a time whilst the engine is hunting, not all of them at the same time of course !

If there is a sensing wire to one bank, transfer it to another bank before disconnecting that battery bank.

 

[[2574]]

I have experienced this with an alternator regulator, not a Balmar, and it was due to a component tolerance in the regulator.

First I would try disconnecting one battery bank at a time whilst the engine is hunting, not all of them at the same time of course !

Could you explain what is meant by Component Tolerance? Was the regulator asking too much of the alternator?

 

[Poey50]

Yes, in the Balmar manual (there are quite a few as I'm sure you aree aware!)

I have the Balmar MC614 which has a wider range of adjustment but yours has a selection of 5 battery types as well as the advanced user-configurable settings. These may not be relevant to your problem but worth knowing what selections you have made or what has been selected on your behalf.

 

[Boater Sam]

Could you explain what is meant by Component Tolerance? Was the regulator asking too much of the alternator?

Any electronic component is made between high and low parameters, When many are joined in a circuit there is a possibility that it will not work because of tolerances adding up even though the design is sound and nothing is faulty.

 

[Alex_Blackwood]

Have you checked your sensing connections

I've a new Balmar 70A alternator which is regulated by a Balmar ARS5 regulator. Fitted last winter. This summer I noticed that our engine (Yanmar75hp), whilst running at low rpm, was constantly changing it's tone, I thought it was fuel starvation or some other mechanical problem as the change in engne sound was positively noticeable. I checked filters and suchlike. Then I happened to notice that the output from the alternator was fluctuating between about 15A and 50A every second or so. The change in load from the alternator was sufficient to change the tone of the engine.

I've been in contact with Balmar and so far they've not been able to provide any guidance as to what the issue might be. It's been suggested that I increase the float voltage but I don't fancy that as it'll cook the new 750AH AGM battery bank. So I'm at a bit of a loss and on the point of swapping out to a different alternator, perhaps a Wakespeed, undecided at present.

If anyone has any experience of anything similar and can provide details of if/how it was resolved I'd be very grateful to read the details.

If you can bear it here is a dropbox link to a video showing the fluctuation of the amperage/voltage as seen on my Victron power monitor. 20220923_151253.mp4

Have you checked your sensing connections. If the the regulator is, intermittently, not seeing a battery due to a loose or bad connection it would cause the fault.

 

[[2574]]

Have you checked your sensing connections

Have you checked your sensing connections. If the the regulator is, intermittently, not seeing a battery due to a loose or bad connection it would cause the fault.

Thanks for that, I have checked but will do so again. The "oscillation" of the charge from the alternator is intermittent, it seems to go away after about half an hour or so, but that doesn't mean its not a loose terminal.

 

[Alex_Blackwood]

Thanks for that, I have checked but will do so again. The "oscillation" of the charge from the alternator is intermittent, it seems to go away after about half an hour or so, but that doesn't mean its not a loose terminal.

I would be inclined to check all connections, throughout the system. "Wiggle" the wires a bit around any crimped connectors . It is surprising what a little bit of high resistance can do. Do it with the system up and running!

 

[Poey50]

Just picking up the voltage sensing issue and thinking about your three battery banks. If these are at different voltages the voltage sensing wire would presumably go just to one. As you say, the additional complication of these might be checked by trying just one bank. And, to expand on Alex Blackwood's point and your reply, 30 minutes might give enough time for thermal expansion to tighten up a flaky connection.

 

[Caladh]

I thought the 70 amp Balmar had an internal regulator (or did) so you disconnect the AR5 and wire correctly for the internal and see what happens ?

 

[Alex_Blackwood]

Just picking up the voltage sensing issue and thinking about your three battery banks. If these are at different voltages the voltage sensing wire would presumably go just to one. As you say, the additional complication of these might be checked by trying just one bank. And, to expand on Alex Blackwood's point and your reply, 30 minutes might give enough time for thermal expansion to tighten up a flaky connection.

I should also have stated the blindingly obvious. It could be a bad connection/dry joint in the regulator!!