Kussmaul 091-120 User Manual

FILE: 091-120-XX-XX-(XXX)(XX).P65

INSTRUCTION MANUAL

Date 09-24-00

R

AUTO CHARGE

3 STEP

AUTOMATIC BATTERY CHARGER

MODEL #091-120-XX-XX-(XXX)(XX)

3 YEAR WARRANTY

KUSSMAUL ELECTRONICS CO., INC.

170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796

TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]

INTRODUCTION

The Auto Charge-3 STEP CHARGER, Model 091-120-XX-XX-(XXX)(XX) is a compact,
completely automatic single channel battery charger designed specifically for periodic
charging. Of rugged construction, the charger is made to withstand the shock and
vibration encountered in vehicle mounted equipment. Utilizing components, which meet
international safety standards, makes this charger ideal for worldwide applications.

BATTERY CHARGER FEATURES

Completely automatic operation, charges battery on demand
Output Voltage regulated, eliminates overcharging battery
Output Voltage, temperature compensated (optional)
Output, current limited to protect charger from overloading
A 5-LED display indicating charge state and faults
Reverse polarity protection

INSTALLATION

The 3 STEP CHARGER should be installed in an area with adequate ventilation.
Mount the charger using the four holes provided.
Connect wiring from the battery to the output terminal strip.
Double check battery wiring. Verify that the battery voltage appears at the charger
output terminals (See Figure 2).

PRINCIPLES OF OPERATION

A three-step lead acid battery charger operates in the three stages described below:

1) A discharged battery is recharged at a constant current (bulk charge) until its volt­age reaches an overcharge level of 2.48 volts per cell. At this time the charger will
switch to Finish Charge. The battery accepts 75-85% of its capacity during bulk
charge.

2) This overcharge voltage is now maintained constant at 2.48 volts per cell (absorp-
tion or finish charge) until the charge current tapers down to {battery capacity/35}
amperes. For the 12 volt, 80 ampere charger this current is 11.9 amperes. The
battery accepts 15-25% of it capacity during absorption charge.

3) Once the charge current reaches the tapered down value (see above), the voltage is
set to a float voltage of 2.24 volts per cell, and maintained at float charge. The
battery is maintained at full charge during float charge, and the green indicator
labeled “Battery Charged” is illuminated.

Figure 1 depicts the above described operation. Note that the term “absorption charge”
is used interchangeably with “finish charge”. Upon application of AC power, the charger
is placed into bulk charge. When the charger switches to finish charge, a timer starts.
In the event that the charge current did not taper down to approximately C/35 amperes
after 2 ½ hours, the charger will automatically go to float charge, and a timeout will be
indicated. This timeout indicator can indicate an old or leaky battery, or it can indicate
that the charger is undersized for the battery being charged.

A battery fault indicator is provided to indicate the absence of a battery, a battery con­nected with reverse polarity, or a battery with an open circuit terminal voltage of less

than 1.35 volts per cell.

TEMPERATURE COMPENSATION

Temperature compensation is provided as an optional feature. A temperature probe is
provided which can be placed in the air surrounding the battery or bonded to the battery
case.