Blue Sea Systems 7621100 Operating instructions

Blue Sea Systems
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
Control
Circuit
7620100 DeutschConnector No 12VDC
7621100 DeutschConnector No 24VDC
PN Termination
Manual
Control
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.
1
2
* 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
1
2
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
ON
OFF
START
ML-SERIES
AUTOMATIC
CHARGING
RELAY
3
+8
-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)
ON
OFF
START
ENGINE
ENGINE
REMOTE (red)
A B
LED (yellow)
ISOLATION #1 (brown)
GROUND (Black)
LED
1
2
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
ON
OFF
START
ML-SERIES
AUTOMATIC
CHARGING
RELAY
3
+8
-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)
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  • Page 4 4

Blue Sea Systems 7621100 Operating instructions

Blue Sea Systems
Brand
Blue Sea Systems
Model
7621100
Category
Motorcycle Accessories
Type
Operating instructions
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