KUSSMAUL AUTO CHARGE LPC, 091-206-12-240 Instruction Manual

FILE: IM_091-206-12-240_revA
REV: A
REVISED BY: THN/PSS
DATE: 06-9-2014

INSTRUCTION MANUAL

AUTO CHARGE

LPC SERIES

MODEL #091-206-12-240

LPC STANDARD DISPLAY

INPUT: 240 volt, 50/60 Hz, 6.5 amps

OUTPUT: 80 AMPERES

3 YEAR WARRANTY

170 Cherry Ave.
West Sayville, NY 11796

www.kussmaul.com

Phone: [phone]

Fax: [phone]

[e-mail]

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS - This manual contains important safety and operating
instructions for battery charger model: 091-206-12.

2. Do not expose the charger to rain or snow.

3. Wire charger inaccordance with all: National, Local and/or Underwriter requirements
for NEMA.

4. Do not operate the charger if it has been dropped or otherwise damaged in any way;

take it to a qualied serviceman.

5. Do not disassemble charger; take it to a qualied serviceman when service or repair is
required. Incorrect reassembly may result in a risk of electric shock or re.

6. To reduce risk of electric shock, disconnect AC input power before attempting
installation, maintenance or cleaning.

CAUTION:

CHARGING LEADS MUST BE DISCONNECTED FROM

BATTERY PRIOR TO WORKING ON CHARGER

7. DC CONNECTION PRECAUTIONS:

a) When connecting DC output wires to the charger always connect to the

charger rst and then to the battery.

b) When disconnecting DC output wires to the charger always disconnect

wires at the battery rst and then disconnect wires at the charger.

8. Charger Location:
a) Locate charger as close to batteries as possible, but not inside the battery
compartment.

b) Never place charger directly above battery or in battery compartment; gases from

battery will corrode and damage charger.

c) Do not operate charger in a closed-in area or restrict ventilation in any way.

e) Do not set a battery on top of charger.

9. Always install high current circuit breaker, supplied with each charger, in-line with the
charger DC output. The circuit breaker should be installed closest to the battery terminal.

10. Always install battery terminal insulators, supplied with each charger, at the charger
DC output terminals.

INTRODUCTION

The AUTO CHARGE LPC SERIES is a low prole, completely automatic, single channel,
battery oat charger designed for vehicles with a single battery system. The LPC improves

upon package size and parasitic systems. The charger is also ruggedized to withstand

the shock and vibration encountered by vehicle mounted equipment.

FEATURES

• Charger controller

• Automatic current limiting

• Remote voltage sense

• Remote charger indicator display

• LED status indicators

• AUX output with AC or DC mode rocker switch and automatic fuse protection

• AC input circuit breaker protection

• Fan cooled

• Reverse polarity protected by external inline fuse

FUNCTIONALITY

Charger Controller:

The Auto Charge LPC contains a precision voltage controller to regulate the output voltage.
Using high-frequency switching technology the output terminal voltage is compared to
a reference voltage, any error detected is then used to control the charger output at the
desired level. There is no “trickle charge” and therefore no danger of overcharging and

water boil-off.

Automatic Current Limiting:

When batteries are severely discharged, some battery chargers can be overloaded due to

the high charging current required. The Auto Charge LPC contains an automatic current
limit circuit. The current limit feature limits the output current to 80 amperes when charging
a deeply discharged battery, or if the starter cranks the engine while charging. The current
limiter thus eliminates the need for an ignition interlock circuit.

Remote Battery Sense:

Adding sense leads from the charger to the battery compensates for voltage drop in the
charging wires. The charger automatically compensates for this voltage drop and boosts
the charger output voltage in order to maintain the voltage at the battery constant.

Remote Charger Indicator Display:

The standard indicator displays the charge condition of the battery in 10-levels from “LOW
CHARGE” to “FULLY CHARGED”. This device indicates a defective battery when a bar
graph does not rise to the “FULLY CHARGED” level after an extended period of charging.

See option accessories for enhanced charger indicator displays. Note: If a battery is being
charged with an external load of 4 to 10 amperes across its terminals, the bar graph may

move down 1 or 2 levels. This does not indicate a defective battery.

LED Status Indicators:

• BATTERY OK: Indicates that a battery of proper polarity is connected to the charger
output terminals.

• AUX ON: Indicates that power to the AUX output terminal is ON.

• AC ON: Indicates that AC input voltage is present. Note: Battery must be above

9VDC and of proper polarity.

AUX Output:

The output terminal strip provides an additional output to accomodate 12 volt accessories,

such as: Kussmaul's 12VDC air pump. The AUX output works in conjunction with a front
panel mounted rocker switch. For normal operation, the rocker switch should be left in AC
mode, which means that the aux accessory works only when shoreline power is supplied
to the charger. With the switch in DC mode the aux accessory will operate when AC power

is ON or OFF. In either position the aux output operates from the vehicle's batteries, while

the charger automatically recharges the batteries as required.

AUX Output Automatic Reset Fuse:

The LPC contains an internal automatic reset fuse. Should the AUX output fuse open,
reset the fuse by cycling the AC input power (shore line). Note: the AUX rocker switch
must be in AC mode.

AC Input Circuit Breaker Protection:

The charger AC input is circuit protected with a panel mounted manual reset circuit breaker.

Cooling Fan:

The LPC is fan cooled and turns on when the charger is on. Air is circulated from the rear
panel and exhusted through the front panel.

Reverse Polarity Protected (only when externally fused):

A surface mounted high current manual reset circuit breaker is provided with each charger.
The circuit breaker must be installed with every charger to provide reverse polarity protection.
If the circuit breaker is not installed then the charger will not be reverse polarity protected.

OPERATION

Battery Charger Output:

1. A discharged battery is recharged to roughly 90% or until the current tapers down

to less than 2 amps. The ouput voltage never exceeds the oat voltage, which is

regulated from 0 to 80 amps (current-limit).

2. The charger will continue to charge the battery until the voltage at the battery reaches
oat voltage level.

AUX Output:

1. The AUX output is current-limited to 15 amps via an internal automatic reset fuse.

The AUX output shares current demand with the battery output. The combination

of both outputs never exceeds 80 amps. If the AUX output demands 15 amps then

the battery output will be limited to 65 amps.

2. The AUX output voltage follows the battery output voltage.

INSTALLATION

Wire # Gauge (awg) 2 12 2 2 12 2 2 12 2

0-5

5-10

10 - 20*

* Consult factory if length of wire to battery is longer than 20 feet

1. The Auto Charge LPC should be installed in a well ventilated area.

2. Mount the charger with the four holes provided.

WIRING

1. Refer to Installation Wiring Diagram.

2. CAUTION: CONNECT DC WIRES TO CHARGER FIRST, THEN TO BATTERIES.

2. Terminate #2AWG or larger cable wire using 5/16" ring lugs, included in hardware
pack. Torque rating 15ft-lb max.

3. Install 100 amp circuit breaker using 5/16 ring lugs in line with BAT (+), included

in hardware pack. Note: Circuit breaker should be placed closest to battery
terminal. Torque rating 50in-lb max.

4. Double check all wiring before applying 240 AC volts to input terminal. Verify that
the battery voltage appears at the charger output terminals. Note: A minimum of
9 volts is required to start the charger.

5. Apply 240 VAC (shoreline power) to input terminal and observe that the charger
is operating. The Remote Bar Graph need not be connected for the charger to

operate.

Length of Wire to Battery (feet)

Battery Charger Connections

V. BAT +

AUX +

COM -

V. BAT +

AUX +

COM -

V. BAT +

AUX +

COM -

INSTALLATION WIRING DIAGRAM

NOTE: Minimum wire size on charger BAT (+) and COM is 2 ,
for a length of 20 feet. Smaller gauge wire may cause overheating of
terminal. Use 2S8R1 5/16” ring lug supplied with each charger to
terminate DC wires to battery. Additional information is available upon request.

# AWG

PIN-2: BLACK

WIRE SIZE

2 AWG

2 AWG

12 AWG

14/3 AWG

PIN-1: RED

PIN-3: WHITE

PIN-4: GREEN

NEGATIVE CHARGING LEAD

POSITIVE CHARGING LEAD

POSITIVE OUTPUT FOR AUX

AC INPUT POWER

COM

BAT +

AUX +

INPUT

DEFINITION

WIRE SIZE CHART

CONNECTION

R

E

M

O

T

E

AUX
12V

BAT O K

AC ON

AUX O N

AC

DC

5

SEN

IND

4

3

2

1

+

_

NEGATIVE OUTPUT FOR AUX

AUX -

12 AWG

A.C. INPUT POWER

GROUND (GRN)

LINE (BLK)

NEUTRAL (WHT)

DC OUTPUT

+

+

Chassis

Ground

Use 5/16 ring lug and M8 x 1.25
hardware, supplied. and Install rubber
terminal insulators over battery cable.

SUPPLIED

100 Amp circuit breaker;

place near battery

AUX+

L

N

AUX

Note: For 240 VAC, pin-4 of indicator must go to pin-5 of
Remote Display on charger.

Note:

.

remote sense
wire cable voltage
compensation

CAUTION:

CHARGING LEADS MUST BE

DISCONNECTED FROM BATTERY

PRIOR TO WORKING ON CHARGER

Use 1/4 ring lug (2X), supplied.

I. FOR BAR GRAPH DISPLAY, 091-200-IND OR DELUXE STATUS CENTER, 091-194C-IND

II. FOR WATERTIGHT DELUXE STATUS CENTER, 091-194C-IND-WT-XX

NOTE: Minimum wire size on charger BAT (+) and COM is 2 ,
for a length of 20 feet. Smaller gauge wire may cause overheating of
terminal. Use 2S8R1 5/16” ring lug supplied with each charger to
terminate DC wires to battery. Additional information is available upon request.

# AWG

WIRE SIZE

2 AWG

2 AWG

12 AWG

14/3 AWG

NEGATIVE CHARGING LEAD

POSITIVE CHARGING LEAD

POSITIVE OUTPUT FOR AUX

AC INPUT POWER

COM

BAT +

AUX +

INPUT

DEFINITION

WIRE SIZE CHART

CONNECTION

RE

M

O

T

E

AUX
12V

BAT O K

AC ON

AUX O N

AC

DC

5

SEN

IND

4

3

2

1

+

_

NEGATIVE OUTPUT FOR AUX

AUX -

12 AWG

A.C. INPUT POWER

GROUND (GRN)

LINE (BLK)

NEUTRAL (WHT)

DC OUTPUT

+

+

Chassis

Ground

Use 5/16 ring lug and M8 x 1.25
hardware, supplied. and Install rubber
terminal insulators over battery cable.

SUPPLIED

100 Amp circuit breaker;

place near battery

AUX+

L

N

AUX

Note: For 240 VAC, pin-4 of indicator must go to pin-5 of
Remote Display on charger.

Note:

.

remote sense
wire cable voltage
compensation

CAUTION:

CHARGING LEADS MUST BE

DISCONNECTED FROM BATTERY

PRIOR TO WORKING ON CHARGER

Use 1/4 ring lug (2X), supplied.

Remote

Indicator

5 - GREEN 22AWG
3 - WHITE 22AWG
2 - BLACK 22AWG
1 - RED 22AWG

OPTIONAL ACCESSORIES

DELUXE STATUS CENTER

MODEL #: 091-194C-IND

DELUXE STATUS CENTER WATERTIGHT

Bezel available in various colors: red, yellow, white, gray, blue, and black

MODEL #: 091-194C-IND-WT

SPECIFICATIONS

Input Power: 240 volt, 50/60 Hz, 6.5 amperes
Input Fuse: 15 ampere, external, manual reset, circuit breaker
AUX Fuse: 15 ampere, internal, automatic, circuit breaker
Float Voltage: 13.25 volts (0 - 80 amps)
Output Current: 80 amperes max
Status Indicators: Battery OK, AUX On, Power On
Charger Indicator: See optional accessories
Hardware Pack: Includes:

(2) 5/16 ring lugs (p/n: 2S8R1) ;
(2) 1/4 ring lugs (p/n: 2S6R1)
(1) 5-pin plug; (1) 2-pin plug
(2) M8 x 1.25 bolt, lockwasher, and nut
(2) Rubber terminal insulators (1-black, 1-red)

(1) 100amp Circuit Breaker (p/n: 090-0100-0)

Weight: 10 pounds

Outline Dimensions: AUTO CHARGE LPC SERIES

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