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Old 31-12-2015, 05:51   #1
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Balmar AT 165 on Volvo Penta MD2030

Hi Folks,

In order to better charge my Batteries (Lithium) I would like to install above mentioned Alternator on my Volvo Penta MD 2030.

Is there anybody who had done the same or similar? Is mounting reasonably straight forward or does it require lots of alternations an the existing mounting for the original alternator?

Also I have a question about the output of the Alternator: looking at the spec sheet the alternator only has its max output beyond 4000 rpm. I usually cruise at 2000 rpm. Is it correct to assume that the alternator makes the same rpm as the motor or does is run faster because the alternator's driving wheel has a lower diameter that the driving wheel of the motor?

Many thanks for your help and advice... and a Happy New Year
Klaus
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Old 31-12-2015, 05:59   #2
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Re: Balmar AT 165 on Volvo Penta MD2030

I have the AT200 installed on an Yanmar.
I recommend going with an serpentine belt setup. And the alternator will spin faster than the engine. How much depend on the size of the pulleys.

Why not go for the AT200? Slightly larger but also more output.

Mine overheats if run at full power so i limit the power using the external regulator.. (charging 1000ah lifepo4)
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Old 31-12-2015, 06:25   #3
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Re: Balmar AT 165 on Volvo Penta MD2030

Thanks for the fast reply.

The AT 200 is an option you are right. However it is slightly larger than the AT165 and I am not sure whether it fits to the MD2030. Did you install your AT200 to the MD2030?

My LFP bank is "only" 400 Ah.

Where did you get the necessary hardware (pullys etc., not the alternator itself) from?

Is the installation straight forward or is it rather complicated?

Interesting idea to limit the output. Which external regulator do you use? Can the MC 614 do this?

Many thanks
Klaus
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Old 31-12-2015, 06:32   #4
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Re: Balmar AT 165 on Volvo Penta MD2030

Moin Klaus, :-)

you might also try to contact Marc Grasser for 'a kit'.

Mark Grasser - DC Power Solutions

You definitely also want a serpentine belt system with a 'high output alternator'.

Regards,

Carsten
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Old 31-12-2015, 06:41   #5
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Re: Balmar AT 165 on Volvo Penta MD2030

I would contact Balmar, they can confirm fitment an pulley recomendations. And yes i belive the Balmar 614 can be set to restrict the alternator.

I use Mastervolt regulator myself.
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Old 31-12-2015, 06:51   #6
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Balmar AT 165 on Volvo Penta MD2030

We have a 6-series Balmar 120A alternator on that engine. For now, we are using the standard single belt to run it. It will not operate at full load with this belt - I had to de-rate it down to 95A. I also had to change the pulley from the 2" supplied to 2.7" in order to provide enough surface contact area to prevent belt slippage.

Doing those two things, along with using high quality belts, allow it operate with only a bit of belt dust being generated. Also, it needs higher rpm to reach full output (because of the pulley change). However, this is not an issue for us because our alternators are a tertiary charging source that are only in use when we are motoring somewhere.

There is no way you will be running a 165A alternator with a 2" pulley on that engine's single belt. Even if you change to a larger pulley, you won't be able to get more than ~100A out of it - and that will be at higher rpm.

You will need a serpentine belt conversion. These are expensive - I'm guessing $700 or so. If you go this route, then get the higher output alternator because that restriction has been removed.

I don't know about the AT series, but our 6 series came with a 1" bushing to make the foot fit the mount. This bushing was drilled for an imperial size bolt, and was too large for the existing bolt - it wouldn't mount securely. I had to make another bushing to fit the engine/bolt.

The alternator/crankshaft pulley ratio is what determines the alternator speed.

Mark
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Old 31-12-2015, 07:22   #7
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Re: Balmar AT 165 on Volvo Penta MD2030

Electromaax is the only company I know of that has a ribbed belt kit for that engine. I helped develop the first one with E-Maax and it was a multi-month ordeal. The timing mark on that engine was the real problem and it was many trips back and forth to the boat to get that kit just right.. An AT165 should work fine provided you have a multi-groove pulley kit. I would recommend starting at Belt Manager level 2 or 3 (de-rates the alt) which should bring you down to about 130-140A....

I am sure Mark could develop one but that timing mark makes it difficult...
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Old 31-12-2015, 07:37   #8
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Re: Balmar AT 165 on Volvo Penta MD2030

... is Electromaxx still in business?

Tried to contact them (both Canada and GB locations) several times over the last 8 weeks with ZERO response.

Now working with Mark to do a kit for a Nanni 4.150HE engine.

Carsten
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Old 31-12-2015, 08:01   #9
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Re: Balmar AT 165 on Volvo Penta MD2030

What is the issue with the timing mark? On ours it is only raised 0.5mm or so. It could be ground down and scribed or punched in instead if needed.

Isn't the serpentine pulley bolted onto the crank pulley anyway?

Balmar also sells them for this engine, although they may just be rebranding EM's.

If I were counting on my alternator as the primary charge source for a Li bank, I wouldn't be messing around with a dual belt pulley and derating the alternator. Or even use a dual belt on a small alternator. I've had these and they suck big time - you never stop fiddling with them trying to keep them working correctly.

Instead, I'd go for a serpentine kit and high output. Even get a higher output and de-rate it only enough to keep it cool.

Mark
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Old 31-12-2015, 09:43   #10
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Re: Balmar AT 165 on Volvo Penta MD2030

Here is a picture of my dual Balmar install.
Also dual 10 groove Serpentine belt.
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Old 31-12-2015, 09:47   #11
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Re: Balmar AT 165 on Volvo Penta MD2030

offpist -- thanks for the picture. super clean!
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Old 31-12-2015, 11:33   #12
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Re: Balmar AT 165 on Volvo Penta MD2030

with 30 engine hp and a 400 AH battery bank you could well get the job done with about an 80A alternator, and external (Mark Grasser or Sterling) remote regulator to maximize it's capability.
That way, you won't have to get into additional drive belt conversions and, as long as your electrical loads aren't excessive (I run refrigeration off a similar sized engine/ battery bank package) you'll be just fine. I have three years, at about 5 mths per year living aboard, on the standard drive belt and it still is in good shape.
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Old 31-12-2015, 11:40   #13
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Re: Balmar AT 165 on Volvo Penta MD2030

That is not a picture of a Volvo MD2030.

Mark
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Old 31-12-2015, 11:48   #14
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Re: Balmar AT 165 on Volvo Penta MD2030

Quote:
with 30 engine hp and a 400 AH battery bank you could well get the job done with about an 80A alternator
On a LiFePO4 bank you want to take advantage of the possible high charging currents.

Carsten
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Old 31-12-2015, 11:55   #15
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Re: Balmar AT 165 on Volvo Penta MD2030

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Originally Posted by colemj View Post
What is the issue with the timing mark? On ours it is only raised 0.5mm or so. It could be ground down and scribed or punched in instead if needed.

Isn't the serpentine pulley bolted onto the crank pulley anyway?


Developing this kit across borders was a royal PITA! E-Maax did not want me to use a local shop for anything as they needed the exact dimensions in Canada to reproduce them.
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