Blue Sea Systems 7621100 Operating instructions

Brand: Blue Sea Systems

Model: 7621100

Category: Motorcycle Accessories

Type: Operating instructions

This manual is also suitable for

7620100 / 7621100 / 7622100 / 7623100

980035700 Rev.001

• Magnetic Latch (ML) - draws very low current in the ON or OFF states, and draws moderate current for very

short time when changing state

•StartIsolation(SI)—canbeconguredfortemporaryisolationofHouseloadsfromEnginecircuitduring

 enginecrankingtoprotectsensitiveelectronics

•EngineIsolation(EI)—canbeconguredforisolationoftwoengineswhilebotharerunningtoprotect

 engineelectronicsandmaximizealternatoroutput

• Senses charging on two battery banks

•LEDoutputtoremotelyindicatewhenbatteriesarecombinedorisolated

•Tin-platedcopperstudsformaximumconductivityandcorrosionresistance

•Labelrecessesforcircuitidentication

•Silveralloycontactsprovidehighreliabilityforswitchingliveloads

• Includes a Remote Control Contura Switch (2146)

• IncludesaDeutschDTMconnector(matingpartnotincludedbutrequired)

Specications  12VDC 24VDC

Wire Size and Current Ratings See table below See table below

ML-Coil Function Bi-stable Bi-stable

AmperageOperatingCurrent continuous <13mA@25°Cnominalvoltage <13mA@25°Cnominalvoltage

  changingstage(20ms) <7A@25°Cnominalvoltage <4A@25°Cnominalvoltage

OperatingVoltage(contacts)  9-16VDC 18-32VDC

ControlVoltage  9-16VDC 18-32VDC

RelayContactPosition:

 -Combine(30sec.)  13.5V 27.0V

 -Combine(90sec.)  13.0V 26.0V

 -OpenLow(10sec.)  12.35V 24.7V

 -OpenLow(30sec.)  12.75V 25.5V

 -OpenHigh  16.2V 32.4V

LiveCurrentSwitching  300A@12VDC-10,000Cycles 150A@24VDC-10,000Cycles

Terminal Stud Size 3/8"-16 3/8"-16

MaximumTerminalStudTorque  140in-lb(15.8N•m) 140in-lb(15.8N•m)

Ring Terminal Size 3/8" (M10) 3/8" (M10)

TerminalRingDiameterClearance 1.18" (30 mm) 1.18" (30 mm)

ControlCircuitCurrentDraw  <40mA <40mA

RemoteControlConturaSwitch

Action     SPDT,ON-OFF-ON

Seals     Internal&ExternalGasketPanelSeal

MountingHole   0.83”x 1.45” (21.08 mm x 36.83 mm)

LEDRating   100,000hourshalf-life

HarnessConnector DeutschDTMSeriesDTM06-6S

MatingPartRequirements   seeLADDIndustriesatwww.laddinc.com

RequiredReceptacleShell  DTM-04-6P

Wedgelock WM-6P

Terminal Pins 1060-20-0122

†

Sealing Plugs 0413-204-2005

†

HandCrimpTooling   DTT-20-0

‡

RegulatoryMeets ISO 8846 and SAE J1171 external ignition protection requirements, CE marked, Rated IP66

* Special modifications are available depending on customer requirements. No polarization on standard product.

† Quantity depends on optional wire connections. The total number of pins and sealing plugs is 6.

‡ Required for hand assembly of wires and terminal pins.

MarineElectricalProd

ucts

PN Termination

Manual

Control

Circuit

7620100 DeutschConnector No 12VDC

7621100 DeutschConnector No 24VDC

PN Termination

Manual

Control

Circuit

7622100 DeutschConnector Yes 12VDC

7623100 DeutschConnector Yes 24VDC

ML– ACR

Automatic Charging Relays



Guarantee

BlueSeaSystemsstandsbehinditsproductsforaslongasyouownthem.

Find detailed information at www.bluesea.com/about. For customer service, call 800.222.7617.

OverviewofApplication

The ML-Series ACR automatically combines batteries during charging, and isolates batteries when there is no

charging sensed on either battery bank.

ML-Series ACR Function 12 Volt DC Operation 24 Volt DC Operation

Automatically combines battery

banks when sensed voltage

levels are:

Above 13.5V for 30 sec.

Above 13.0V for 90 sec.

Above 27.0V for 30 sec.

Above 26.0V for 90 sec.

Automatically isolates battery

banks when sensed voltage

levels are:

Below 9.6V (undervoltage lockout)

Below 12.35V for 10 sec.

Below 12.75V for 30 sec.

Above 16.2V (overvoltage lockout)

Below 19.2V (undervoltage lockout)

Below 24.7V for 10 sec.

Below 25.5V for 30 sec.

Above 32.4V (overvoltage lockout)

StartIsolationorEngineIsolation.Theisolationinputsenableoneoftwofunctionsdependingon

howtheinputsarecongured.

NOTE: The ML-Series ACR can be congured for Start Isolation or Engine Isolation, but not both.

• StartIsolation-Temporaryisolation(3−5 minutes) of house loads from the engine circuit during engine

 crankingtoprotectsensitiveelectronics.CongureStartIsolationwhenthereareheavycrankingloads

 causingsagsandspikesthatmightdamageelectronicsintheHousecircuit.Seepage3.

• EngineIsolation-Isolatetwoengineswhilebotharerunningtoprotectengineelectronics,andto

 maximizealternatoroutput.CongureEngineIsolationwhentheenginemanufacturerrequiresit,and

 whenthereareseparatebatteriesforeachengine.Seepage3.

UndervoltageorOvervoltageLockout.

• Undervoltagelockoutpreventsbatteriesfrombeingcombinedwheneitherbatteryisbelow9.6V@12VDC

 operationor19.2V@24VDCoperation.

• Overvoltagelockoutpreventsbatteriesfrombeingcombinedwheneitherbatteryisabove16.2V@12VDC

 operationor32.4V@24VDCoperation.

ControlSwitchRemoteOperation. OptionalConturaControlSwitch—sustained(SPDT)ON-OFF-ON.

TheControlSwitchshouldbemountedinaconvenientlocationnearhelmcontrolstoallowforquickaccess.

NOTE: Alternatively use a momentary (SPDT) (ON)-OFF-(ON) or momentary push button switch to provide cross connect and/or battery isolation.

To cross connect

(combine) battery banks

Switchto“ON”combinesbatterybankstoprovidemorebatterypowerinhard

starting situations.

To isolate battery banks

Switch to “OFF”- when the battery banks are isolated using the Control

Switch, the battery banks remain isolated, and for at least 30 seconds after

thecontrolswitchisreturnedtothe“AUTO”position.

ControlSwitchRemoteIndicationorML-ACRStatus

NOTE: The remote switch has two LEDs (top and bottom). These LEDs operate simultaneously-either they are both ON or both OFF.

page1of4

LEDINDICATION ACRSTATEORCONDITION

RemoteSwitchSetto“AUTO”ornoRemoteSwitchInstalled

LEDsOFF Batteries are isolated

LEDsON Batteries are combined

LEDsslowsteadyblink,ON-OFF StartorEngineIsolationiscausingbatteriestobeisolated

LEDsquicksteadyblink,ON-OFF

Undervoltage lockout--either battery is below 9.6V@12V DC

operation or 19.2V@24V DC operation.

Overvoltage lockout--either battery is above 16.2V@12V DC

operation or 32.4V@24V DC operation.

RemoteSwitchSettoOVERRIDE“ON”or“OFF”—Automaticoperationissuspendedfor10minutes

afterremoteswitchisreturnedto“AUTO”

LEDsdoubleblink,

Blink-Blink-Pause,Repeat

Manual override--check ACR for switch states OR

ACR mechanical failure

WireSizeandCurrentRatings

Wire Size

Cranking

30 sec.

Intermittent

5 min.

Continuous

(UL 1107)

2/0AWG(70mm²) 1,000A 400A 225A

4/0AWG(120mm²) 1,100A 400A 300A

2×4/0AWG(2x120mm²) 1,450A 700A 500A

Blue Sea Systems, Inc.

4600 Ryzex Way

Bellingham, WA

98226 USA

Phone 360.738.8230

www.bluesea.com

InstallationInstructions

Mounting

InstalltheML-SeriesACRascloseaspossibletobothbatterybankssothatpositiveandnegativewiresare

asshortaspossible,andvoltagedropinthesewiresiskepttoaminimum

‡

. To avoid corrosion to terminals

andconnectingwires,mountinadryandprotectedlocation.Avoidmountingdirectlyaboveventedleadacid

batteriessothattheACRisnotexposedtocorrosivegassesexpelledfromthebatteries.

‡

BecausetheACRsensesthevoltagebetweenitsnegativegroundconnectionanditspositivesense

 connections,bothpositiveandnegativewiresshouldbeasshortaspossiblesothattheinuenceof

 voltagedroponsensedvoltagelevelsisminimized.

HighCurrentPrimaryCircuitConnections(studterminalsAandB)

Forhelpselectingtheappropriatewiresizeandcircuitprotectionrating,gotowww.bluesea.comandclickthe

Circuit Wizardquicklink.

Toconnecthighcurrentcircuitwires:

1. Connect the battery banks to the stud terminals marked A and B.

2.Torquethehighcurrentterminalstudnutsto140in-lbs(15.5N•m)maximum.

NOTES:StudterminalsAandBareinterchangeable.EitherbatterybankcanbeconnectedtoAorB.

If the ACR is to be used for cross connect, fuses between ACR terminals A and B and each battery

  positivearenotrequiredaccordingtoABYCguidelines.IftheACRisnotusedforcrossconnect,

  installfusestopreventahazardifthereisdamagetothewiresconnectingthebatteriestothe

  ACR.Thefusesshouldbeplacedascloseaspossibletothebatteriessothatmostofthewire

  isprotected.

ControlCircuitConnection(wirecontainedinthewireharness)

GroundConnection

ConnecttheblackwireinthewireharnesstoDCgroundatthemaingroundterminalbusbar.

OptionalControlCircuitConnections(wirescontainedinthewireharness)

CrossConnectorIsolateBatteryBanks

Use asustained(SPDT)ON-OFF-ONRemoteControlSwitch(soldseparately)

Alternativelyamomentary(SPDT)(ON)-OFF-(ON)RemoteControlSwitch,ortwomomentarypushbutton

switches(soldseparately)canprovidecrossconnectand/orbatteryisolation.TheControlSwitchshouldbe

mountedinaconvenientlocationnearhelmcontrolstoallowforquickaccess.

NOTE:Use16AWG

wire for all Control Circuit connections to meet ABYCminimumwiresizerequirement.

CrossConnectorIsolateBatteryBanksUsingOptionalControlSwitch

 UseControlSwitch(soldseparately)–momentaryorsustainedsinglepoledoublethrow(SPDT)toprovide

these settings:

 • CROSSCONNECT ( I)-Batterybanksarecombinedtoprovidemorebatterypowerinhard

starting situations.

 • ISOLATE (O) - Battery banks are isolated until the Control Switch is returned to AUTO(centerposition).

When the Control Switch is returned to AUTO, the ACR returns to automatic mode.

Toenablecrossconnectandisolation,connect:

 • Redwirefromharnesstocenter(common)ofSPDTswitch.

• CrossConnectterminalofSPDTswitchtoDCpositivethrough2Acircuitprotection.

• IsolateterminalofSPDTswitchtoDCnegative(ground).

 Toenabletemporarycrossconnectusingmomentarypush-buttonswitch:

 • Connecttheredwirefromtheharnesstoonesideofamomentarypush-buttonswitch,(soldseparately).

 • ConnecttheothersideofthepushbuttonswitchtoDCpositivethrough2Acircuitprotection.



OverviewofApplication(continued)

page2of4980035700 Rev.001

 Theseinstructionsareintendedtoprovideassistancewiththeinstallationofthisproduct,andare 

 notasubstituteforamorecomprehensiveunderstandingofelectricalsystems.Westrongly

 recommendthatacompetentelectricalprofessionalperformtheinstallationofthisproduct.

Theillustratedwiringdiagramrepresentsacommoninstallationandisnotmeanttobeaguideforwiring

 aspecicvessel.Thewiringdiagramshowsasinglebatterybankinstallation.

Disconnectallnegativebatteryconnectionsbeforebeginningtheinstallation.

All unused control wires should be carefully insulated from each other and from accidental contact

 usingheatshrinktubingorelectricaltape.Externalcontactorshortingbetweencontrolwirescanlead

to malfunction.

CAUTION

ManualControlOverrideKnobPN7622B/7622100B/PN7623B/7623100B

TheManualControlOverrideKnobprovides:

• anaddedlevelofsafetythatallowsmanualON-OFFcontrolwithorwithoutpower

• LOCK OFF for servicing the electrical system

RemoteLEDsincontrolswitchindicatewhenML-SeriesACRisinmanualoverridecondition.

ManualControlOverrideKnobOperations*

†



To combine battery banks

WithOverrideKnobinREMOTEposition,

pushbuttonuntillatched(PushtoLatchOn).

To isolate battery banks that

are connected

Rotate Override Knob to right to release button

fromLatchOnmode(buttonpopsup).Rotate

OverrideKnobtoleft(REMOTEposition).

Topreventremoteoperation

Rotate Override Knob to right

(LOCKOFFposition).

To secure for servicing

WithOverrideKnobinLOCKOFFposition,

passcabletiethroughhole.

* OperatingtheManualControlOverrideKnobwilloverrideautomaticoperationoftheML-SeriesACRfor

10 minutes if the override forces a change in switch state.

†

TheML-SeriesACRwillwait10minutesifitattemptstoautomaticallyclosewhilethemanualknobis

rotated to LOCK OFF.

InstallationInstructions(continued)

page3of4980035700 Rev.001

InstallationInstructions(continued)

Legend

Optionalconnection

Legend

Optionalconnection

EngineIsolation

TheML-SeriesACRcanbeconguredtoautomaticallyopenwhentwoenginesaresimultaneouslyrunning

toensurethattworunningenginesareneverelectricallyconnected.Enablethisfeaturetoreduce 

noiseandcommunicationcross-talkbetweenengines,andtomaximizetotalpotentialalternatoroutput.

ToenableEngineIsolationfortwoengines:

• Connect the brown wire (ISOLATION #1) from the harness to the ON terminal of the start key switch on

  oneengine.Makethisconnectionthrougha2Ampin-linefuse.Thisconnectionmustbetothelinethat

  ispositivewhiletheengineisnormallyrunning.

 • Connectthegreenwire(ISOLATION#2)toENGINE#2inthesamemannerasabove.

ToenableEngineIsolationforthreeengines:

 • Connectthebrownwire(ISOLATION#1)toENGINE#1,thegreenwire(ISOLATION#2)toENGINE#2,and

  theorangewire(ISOLATION#3)toENGINE#3inthesamemannerasabove.

StartIsolation

TheML-SeriesACRcanbeconguredtoautomaticallyopentemporarily(3-5minutes)whenvoltageis

sensedonanyoneofuptothreestart-isolationinputs.EnablethisfeaturetoisolateStartcircuitsfromthe

Housecircuitandpreventstartingcurrenttransientsfrominterferingwithsensitivehouseelectronics.

ToenableStartIsolation:

• Connect the brown wire (ISOLATION #1) from the harness to the terminal or wire running from the start

  keyswitchtothestartersolenoid.Makethisconnectionthrougha2Ampin-linefuse.Thisconnection

  canbemadeatthestartkeyswitchoratthestartersolenoid,butmustbetothelinethatispositiveonly

when cranking the engine. as shown below.

ToenableStartIsolationfortwoorthreeenginesstartingfromthesamebattery:

 • Connectthegreenwire(ISOLATION#2)toENGINE#2inthesamemannerasabove.

 • Connecttheorangewire(ISOLATION#3)toENGINE#3inthesamemannerasabove.

StartIsolationInstallation

EngineIsolationInstallation

REMOTE (red)

A B

LED (yellow)

ISOLATION #1 (brown)

GROUND (Black)

LED

START

BATTERY

ML-SERIES

REMOTE

BATTERY

SWITCH

ML-SERIES

REMOTE

BATTERY

SWITCH

HOUSE

BATTERY

HOUSE

DISTRIBUTION

ISOLATION #2 (green)

ISOLATION #3 (orange)

2 AMPS

ENGINE

START

SWITCH

OFF

START

ML-SERIES

AUTOMATIC

CHARGING

RELAY

-7

LED

NOTE: The remote

switch has two LEDs.

These LEDs operate

simultaneously and

are either both ON

or both OFF.

NOTE: Use circuit protection

only if ACR is not used for

emergency cross-connect.

REMOTE (red)

LED

(yellow)

ISOLATION #1 (brown)

ISOLATION #2 (green)

ISOLATION #3 (orange)

GROUND (Black)

OFF

START

ENGINE

REMOTE (red)

A B

LED (yellow)

ISOLATION #1 (brown)

GROUND (Black)

LED

START

BATTERY

ENGINE

ML-SERIES

REMOTE

BATTERY

SWITCH

ML-SERIES

REMOTE

BATTERY

SWITCH

HOUSE

BATTERY

HOUSE

DISTRIBUTION

ISOLATION #2 (green)

ISOLATION #3 (orange)

2 AMPS

ENGINE

START

SWITCH

OFF

START

ML-SERIES

AUTOMATIC

CHARGING

RELAY

-7

LED

NOTE: The remote

switch has two LEDs.

These LEDs operate

simultaneously and

are either both ON

or both OFF.

NOTE: Use circuit protection

only if ACR is not used for

emergency cross-connect.

REMOTE (red)

LED

(yellow)

ISOLATION #1 (brown)

ISOLATION #2 (green)

ISOLATION #3 (orange)

GROUND (Black)

DTM06-6S

CONNECTOR

INCLUDEDWITH

PRODUCT

DTM04-6PUSER

MUST SUPPLY

DTM06-6S

CONNECTOR

INCLUDEDWITH

PRODUCT

DTM04-6PUSER

MUST SUPPLY

4.Remoteindicatorlamp(Optional)

 UseBlueSeaSystemsLED8033(amber),8171(red),or8172(green).

ToinstallaremoteLEDindicator:

 • Connectswitchpin8toDCpositiveprotectedbya2Ampin-linefuse.

 • Connectpin7totheyellowwirefromtheharness.

4.50"

114.30mm

3.00"

76.20mm

5.47"

138.94mm

3.75"

95.25mm

2.03"

51.56mm

1.90"

48.26mm

1.03"

26.16mm

page4of4980035700 Rev.001

InstallationInstructions(continued)

Blue Sea Systems 7621100 Operating instructions

Brand: Blue Sea Systems

Model: 7621100

Category: Motorcycle Accessories

Type: Operating instructions

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Blue Sea Systems 7621100 Operating instructions

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