Kussmaul 091-127 User Manual

FILE: IM_091-127-XXX-YY-TC-HL-UV_Rev_A.P65
Date: 06-24-03

INSTRUCTION MANUAL

R

AUTO CHARGE

3 STEP

AUTOMATIC BATTERY CHARGER

MODEL #091-127-XXX-YY-(ZZZ)(WW)

XXX - 12, 24, 32, 36, 48, 72, 96, 120 and 144 VDC
YY - 8, 10, 15, 20, 27, 30, 40 and 80 Amps

ZZZ -115VAC 60Hz, 230VAC 60Hz, 230VAC 50Hz
WW - TC, HL and UV Options

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 091-127-XXX-YY-(ZZZ)(WW) is a compact,
completely automatic single channel battery charger designed specifically for periodic
charging. Refer to Specifications section of this manual for Model Number Composition.
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 (Option)
Output, current limited to protect charger from overloading
A 5-LED display indicating charge state and faults
Reverse polarity protection
Under voltage signaling (Option)
Selectable HIGH/LOW Output Current (Optionl)

Refer to Specifications section of this manual to incorporate "Options" in Model Number
Composition.

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 (absorption
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 time-out will be indicated. This
time-out 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.

SELECTABLE OUTPUT CURRENT

Selectable output current level is provided as an optional feature. It is normally supplied as
a current output level "HIGH" and "LOW" front panel switch selectable setting. Unless
otherwise specified the "HIGH" current setting refers to unit maximum output currrent as
specified in Specifications section of this manual. The "LOW" current setting is 40% +/- 5%
of the maximum current ouput. Consult factory for additional information on this option.