Blue Sea Systems 7621 Operating instructions

Brand: Blue Sea Systems

Model: 7621

Category: Motorcycle Accessories

Type: Operating instructions

This manual is also suitable for

ML– ACR

Automatic Charging Relays

PN 7620 / PN 7621 (without manual control)

PN 7622 / PN 7623 (with manual control)

990180180 Rev.005

• 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

Specications 12V DC 24V DC

Cranking Rating See table below See table below

Intermittent Rating See table below See table below

Continuous Rating 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)  19-6VDC 18-32VDC

ControlVoltage  19-6V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 Switch 2146

Action Sustained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

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

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.

MarineElectricalProd

ucts

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. Included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

PN Termination

Manual

Control

Circuit

7620 Tinned Wires No 12VDC

7621 Tinned Wires No 24VDC

PN Termination

Manual

Control

Circuit

7622 Tinned Wires Yes 12VDC

7623 Tinned Wires Yes 24VDC

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theincludedControlSwitch—sustained(SPDT)ON-OFF-ON.

Alternativelyuseamomentary(SPDT)(ON)-OFF-(ON)ormomentarypushbuttonswitch(soldseparately)to

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–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.

page2of4

Overview of Application (continued)

To Connect Sustained (SPDT) ON-OFF-ON Contura Control Switch:

1.Connectpin3oftheControlSwitchtoDC+througha2A(min)circuitprotectiondevice.

2.Connectpin1toDCground.

3.Connectpin2toACR“REMOTE”wire(red).

4.Connectpin8toDC+througha2A(min)circuitprotectiondevice.

5.Connectpin7toACR“LED”groundwire(yellow).

1.965"

49.91m

1.010"

25.65mm

.549"

13.95mm

1.125"

28.58mm

TEST CUT

HOLE IN

ACTUAL

CENTER

1.450"

36.83mm

0.830"

21.08mm

 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 7622 / PN 7623

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.

990180180 Rev.005

REMOTE (Red)

LED (Yellow)

ISOLATION #1 (Brown)

GROUND (Black)

LED

START

BATTERY

ENGINE

ML-SERIES

REMOTE

BATTERY

SWITCH

HOUSE

BATTERY

HOUSE

DISTIBUTION

ISOLATION #2 (Green)

ISOLATION #3 (Orange)

2 AMPS

ENGINE

START

SWITCH

OFF

START

-7

ENGINE

START SWITCH

OFF

START

ML-SERIES

REMOTE

BATTERY

SWITCH

ML-SERIES

AUTOMATIC

CHARGING

RELAY

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.

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.

990180180 Rev.005

page3of4

REMOTE (Red)

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.

Installation Instructions

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

Installation Instructions (continued)

Engine Isolation Installation

Legend

Optionalconnection

Legend

Optionalconnection

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

Installation Instructions (continued)

page4of4

990180180 Rev.005

Blue Sea Systems 7621 Operating instructions

Brand: Blue Sea Systems

Model: 7621

Category: Motorcycle Accessories

Type: Operating instructions

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