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: 631-567-5826
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.
UNDER VOLTAGE
Under Voltage signaling is provided as an optional feature. It is supplied as relay contact
closures internal to the charger in accordance with the following specifications.
Interface Voltage and Current Rating: per NEMA Classification for AWG 18 wire and
Customer Interface distance.
Consult Factory for Under Voltage "Set-Point" threshold and signal hysteresis characteristics for Under Voltage signaling equipped models. Consult Factory for field adjustment of
Under Voltage Set-Point threshold.
UV RELAY: Refer to Figure 2
Energized [COM makes NO] when battery terminal voltage is ABOVE Under Voltage Set-
Point plus signal hysteresis.
De-energized [COM makes NC] when battery terminal voltage is EQUAL to or BELOW
Under Voltage Set-Point.
THREE STAGE CHARGING CURVE
ABSORPTION STAGE
BATTERY
CURRENT
BATTERY
VOLTAGE
FLOAT
STAGE
Voltage Increasing
Current Constant
STAGE I
CONSTANT CURRENT
(BULK)
Voltage Constant
Current Decreasing
STAGE II
CONSTANT VOLTAGE
(ABSORPTION)
Figure 1
Voltage Constant
Full Charge Maintained
STAGE III
CONSTANT VOLTAGE
(FLOAT)
TIME
NOTE: This charger is designed to have it’s output voltage compensated for changes in
Temperature. A switch on the circuit board selects wh ether the unit is operated in the
compensated or uncompensated mode. WHEN IN THE TE MPERATURE COMPENSATED
MODE THE THERMISTOR MUST BE CONNECTED. Operation without the thermistor
while in the compensated mode will result in loss of voltage control and overcharging
of the battery.
UV RELAY Customer Interface
(Optional)
White
COM
Green
NC
Black
NO
OUTPUT
CURRENT
HIGH/LOW
SWITCH
(OPTIONAL)
A.C. POWER
THERMISTOR
(OPTIONAL)
-
+
BATTERY
Figure 2
INSTALLATION WIRING
Specifications
Input Power:& Fuse: See Chart
Output Power: See Chart
Charge Indicator: See Chart
Mode Indicators: Battery Fault, Time-out, Bulk Charge, Finish Charge, and Battery Charged
Recommended Battery Size: See Chart
Weight: 65 pounds
Temperature Compensation: Add suffix “TC” to Model Number shown in Table below
Output Current Select: Add suffix "HL" to Model Number for selectable output current levels.
Under Voltage: Add suffix "UV" to Model Number for Under Voltage signaling option.
Fifty (50) Hz Operation: 230VAC input power operation only. Add "/50" as suffix to 230
in Model Number for 50Hz operation. Example: 091-127-XXX-YY-230/50.
Model Number Composition:
091-127-XXX-YY-ZZZ-WW
Options: TC, HL, UV
Input: Omit for 115VAC 60Hz
230 for 230VAC 60Hz
230/50 for 230VAC 50Hz
Output Amperes
Output Volts, DC
Model Number Input Power Input Fuse Output Charge Recommended
091-127- X X X- Y Y VAC, Fr eq ,, C ur r e nt Amps, Type
091-127-12-80 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 12 Volts, 80 A mps 100 Ampere 300 to 600 ampere- hour s
091-127-24-40 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 24 Volts, 40 Amps 50 Ampere 150 to 300 ampere-hours
091-127-32-30 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 32 Volts, 30 Amps 50 Ampere 110 to 220 ampere-hours
091-127-36-27 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 36 Volts, 27 Amps 50 Ampere 100 to 200 ampere-hours
091-127-48-20 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 48 Volts, 20 A mps 25 Ampere 75 to 150 amper e-hour s
091-127-72-15 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 72 Volts, 15 A mps 25 Ampere 50 to 100 amper e-hour s
091-127-96-12 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 96 Volts, 12 Amps 25 Ampere 45 to 90 amper e hours
091-127-120-10 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 120 Volts, 10 Amps 25 Ampere 40 to 80 ampere hours
091-127-144-8 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 144 Volts, 8 Amps 25 Ampere 40 to 80 ampere hours
091-127-12-80-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 12 Volts, 80 Amps 100 Ampere 300 to 600 amper e- hours
091-127-24-40-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 24 Volts, 40 Amps 50 Ampere 150 to 300 ampere-hours
091-127-32-30-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 32 Volts, 30 Amps 50 Ampere 110 to 220 ampere-hours
091-127-36-27-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 36 Volts, 27 Amps 50 Ampere 100 to 200 ampere-hours
091-127-48-20-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 48 Volts, 20 Amps 25 Ampere 75 to 150 ampere-hours
091-127-72-15-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 72 Volts, 15 Amps 25 Ampere 50 to 100 ampere-hours
091-127-96-12-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 96 Volts, 12 Amps 25 Ampere 45 to 90 ampere hours
XXX Volts, YY Am ps
Indicator Battery Size
091-127-120-10-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 120 Volts, 10 Amps 25 Ampere 40 to 80 ampere hours
091-127-144-8-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 144 Volts, 8 Amps 25 Ampere 30 to 60 ampere hours
OUTLINE DRAWING
SWITCH S1
PLACE IN
T/C POSITION
WHEN INSTALLING
THERMISTOR
TST-110-01-T-S CONNECTOR
FAR SIDE
FIGURE 3
THERMISTOR INSTALLATION SW I TCH SET T ING
INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
WARRANTY
All product of Kussmaul Electronics Company Inc. are warranted to
be free of defects of material or workmanship. Liability is limited to repairing or replacing at our factory, without charge, any material or defects
which become apparent in normal use within 3 years from the date the
equipment was shipped.
Kussmaul Electronics Company, Inc. shall have no liability for damages of any kind to associated equipment arising from the installation and
/or use of the Kussmaul Electronics Company, Inc. products. The purchaser, by the acceptance of the equipment, assumes all liability for any
damages which may result from its installation, use or misuse, by the
purchaser, his or its employees or others.
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