Kussmaul 091-139-2-12 User Manual

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Page 1

FILE: 091-139-002

REV.A: 2/24/04

DATE: 04-23-01

INSTRUCTION MANUAL

AUTO ISOLATOR I

AN AUTOMATIC LOSSLESS BATTERY ISOLATOR

FOR DUAL BATTERY SYSTEMS

MODEL# 091-139-2-12

BATTERY VOLTAGE: 12 VDC

OUTPUT: 12 VOLTS, 3 AMPS

BATTERY PARALLELING SOLENOID: 200 AMPS

3 YEAR WARRANTY

Page 2

INTRODUCTION

The Model 091-139-2-12 AUTO ISOLATOR I system is a lossless isolator replacement for the conventional diode isolator. Designed to be installed in a vehicle with one or more Main batteries that must be isolated from one or more auxiliary batteries. The system consists of a voltage detector and controller Model 091-139-CONT-12 and a separate 200-ampere rated solenoid, Model 091-139-SOL-12HO for switching the batteries. In addition to maintaining battery isolation the AUTO ISOLATOR I may parallel the batteries on engine starting if the auxiliary battery has sufficient charge to assist in the cranking. A block diagram of the system appears in figure 1.

STARTER

PUSH BUTTON

STARTER

ISOLATOR

ALTERNATOR

MAIN BATT ERY SENSE

AUXILIARY BATTERY SENSE

POWER

IGNITIO N

SWITCH

PARALLELING

SOLENOID

DRIVER

SOLENOID

STARTER

SOLENOID

MAIN

BATTERY

AUXILIARY

BATTERY

MAIN BATTERY VOLTAGE

DETECTOR

AUX.

BATTERY VOLTAGE

DETECTOR

TIMER

Figure 1

Block Diagram

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SYSTEM OPERATION

The system receives its power from the ignition switch. With the switch “OFF” all the power is removed from the system and the solenoid is deenergized.

As soon as the operator turns the ignition “ON”, the system is powered and detects the voltage of the main and auxiliary batteries. If the auxiliary battery voltage is 12.4 volts or greater, (indicating sufficient charge) cranking the engine will cause the paralleling solenoid to be energized. A 10-second timer will maintain the paralleling solenoid if the engine doesn’t start immediately and must be cranked a second time. When the engine starts the alternator output raises the battery voltage. This increase in voltage is detected and the paralleling solenoid is held energized charging both batteries.

If when the engine is started the auxiliary battery voltage is below 12.0 volts the paralleling solenoid is not energized while cranking. As soon as the engine starts, the alternator raises the main battery voltage and the solenoid is energized charging both batteries.

Upon engine shutdown the ignition switch is placed in the “OFF” position. Power is removed from the Auto Isolator and the solenoid is deenergized.

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INSTALLATION

Install the 091-139-CONT-12 Controller is a suitable location protected from the weather and engine heat. The 091-139-SOL-12HO Solenoid may be mounted in the engine compartment or at a location to minimize the length of the battery cables. Install wiring per figure 2.

THIS LINE ENERGIZES THE SOLENOID AT ENGINE START IF THE AUXILIARY BATTERY HAS SUFFICIENT VOLTAGE TO PROVIDE A BOOST

THIS LINE SUPPLIES THE POWER TO OPERATE THE SYSTEM

AUTO ISOLATOR I CONTROLLER

091-139-CONT-12

12VOLT

GNITION

WITC

1 2 3 4 5 6 7 8

PARALLELING

SOLENOID

SENSE LINE, CONNECT DIRECTLY TO BATTERY

NOTE POLARITY OF

MAIN

BATTERY

FLYBACK DIODE

ALL WIRES #16 AWG EXCEPT AS NOTED

Note: Red Dot

SENSE LINE, CONNECT DIRECTLY TO BATTERY

#2 AWG MIN.

+12VOLT FROM STARTE

AUXILIARY

BATTERY

Figure 2

AUTO ISOL ATOR I

Mode l 09 1- 1 39 -1 2

INSTALLATION WIRING

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CALIBRATION

The voltage setpoints may be altered in the field to suit particular customer requirements. Adjustments are provided to adjust the main battery voltage at which the paralleling solenoid is energized. An additional adjustment permits adjusting the voltage below which the auxiliary battery will not be paralleled for starting boost.

INDICATOR ILLUMINATED WHEN MAIN BATTERY VOLTAGE IS ABOVE SETPOINT

13.3 VOLTS

CW INCREASES VOLTAGE

AUXILIARY BATTERY VOLTAGE ADJUST

MAIN BATT ERY VOLTAG E ADJUST

MAIN AUX.

OUTPUT

CR3

CR4

CI1 R10

CR1

VCC+

CR2

INDICATOR ILLUMINATED WHEN AUXILIARY BATTERY VOLTAGE IS ABOVE SETPOINT, 12.0 VOLTS

R15

R13

R18

MAIN

R19

GND

R17

R21R1

KUSSMAUL ELECTRONICS CO

AUX

B091- 139- 002

R16

87654321

MAIN BAT. OK

AUX.

BAT. OK

R20

R12

R11

ILLUMINATES DURING ENGINE CRANKING

STARTER

MEASURE AUX. BAT. VOL TAGE HERE

MEASURE MAIN BAT. VOLTAGE HERE

Figure 3

VOL TAGE ADJUSTMENTS

AUTO ISOLATOR 1

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SPECIFICATION AND OUTLINE

CONTROLLER, Model 091-139-CONT12 Volts to parallel: 13.3 volts, field adjustable Battery load: .000125 amps. Output current: 3 amps Weight: .4 lbs.

SOLENOID, Model 091-139-SOL-12HO Volts: 12 volts D.C. Coil current: .65 amps Contact rating: 200 amps

5.10

3/16" DIA.

2.95

4,50

1.55

OUTLINE, AUTO ISOLATOR I CONTROLLER, 091-139-CONT12

3.60

3.30

2.80

OUTLINE, AUTO ISOLATOR I SOLENOID, 091-139-SOL-12HO

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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. Equipment is to be returned, shipping charges prepaid and will be returned, after repair, shipping charges paid.

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 lia bility for any damages which may result from its installation, use or misuse, by the purchaser, his or its employees or others.