KUSSMAUL 091-120-12-20, 091-120-36-8, 091-120-24-12, 091-120-32-9, 091-128-48-6 Instruction 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)

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]

3 YEAR WARRANTY

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.

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

CHARGING WIRE SIZE

VOLTS AWG

12

10

BATTERY FAULT

TIMEOUT

BULK CHAR GE

FINISH CHARG E

BATTERY CHARGED

24
32
36

48
72
96

120

12

12

14
16
16
16

16

A.C. INPUT

POWER

BLACK

WHITE
GREEN

FUSE

INPUT

LN

BAT

TEMP. SENSEOUTPUT

+

#2 #1

+

BATTERY

-

THERMISTOR(OPTIONAL)

Figure 2

INSTALLATION WIRING

Specifications

Input Power & Fuse: See Chart
Output Power: See Chart
Charge Indicator: See Chart
Mode Indicators: Battery Fault, Timeout, Bulk Charge, Finish Charge, and Battery Charged
Recommended Battery Size: See Chart
Weight: 22 pounds
Temperature Compensation: Add suffix “TC” to Model Number shown in Table below

Model Number Input Power Input Fuse Output Charge Recommended

091-120-12-20 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 12 Volts, 20 Amps 25 Ampere 75to 150 ampere-hours
091-120-24-12 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 24 Volts, 12 Amps 15 Ampere 40 to 80 ampere-ho urs

091-120-32-9 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 32 Volts, 9Amp s 15 Ampere 30 to 60 ampere-hours
091-120-36-8 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 36 Volts, 8Amp s 15 Ampere 27 to 54 ampere-hours

091-128-48-6 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 48 Volts, 6Amp s 8 Ampere 20 to 40 ampere-ho urs
091-128-72-4 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 72 Volts, 4Amp s 8 Ampere 13 to 26 ampere-ho urs

091-128-96-3 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 96 Volts, 3Amp s 4 Ampere 10 to 20 ampere-hours

091-128-120-2 1 15Volts 60 Hz, 6 Amps 8 amp Slow Blow 120 V olts,2 Amps 4 Ampere 7.5 to 15 ampere-hours

091-120-12-20-230 230 V olts60Hz, 3 Amps 5 amp Slow Blow 12 Volts, 20 Amps 25 Ampere 75to 150am pere -hours
091-120-24-12-230 230 V olts60Hz, 3 Amps 5 amp Slow Blow 24 Volts, 12 Amps 15 Ampere 40 to 80 ampere-hours

091-120-32-9-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 32 Volts, 9Amps 15 Ampere 30 to 60 ampere-hours
091-120-36-8-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 36 Volts, 8Amps 15 Ampere 27 to 54 ampere-hours

091-128-48-6-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 48 Volts, 6Amps 8 Ampere 20 to 40 ampere-hours
091-128-72-4-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 72 Volts, 4Amps 8 Ampere 13 to 26 ampere-hours

Indicator Battery Size

091-128-96-3-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 96 Volts, 3Amps 4 Ampere 10 to 20 ampere-hours

091-128-120-2-230 230 V olts60Hz,3 Amps 5 amp Slow Blow 120 Volts, 2 Amps 4 Ampere 7.5 to 15 ampere-hours

9/32" D IA.

12.7512.00

4.75

6.75

4.25

OUTLINE DRAWING

INSTALLATION RECORD & WARRANTY

Date Installed

Installed By

Vehicle Identification

Vehicle Owner

WARRANTY

All products 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 employes or others.