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file: 091-89-12.p65
Rev.A
10-27-2004
INSTRUCTION MANUAL
AUTO CHARGE
4000
AUTOMATIC BATTERY CHARGER
MODEL #091-89-12
NOTE : This charger is designed for vehicles with
dual batteries and negative ground.
INPUT :120 volt, 50/60 Hz, 8 amps
OUTPUT: 40 AMPERES
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
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INTRODUCTION
The Auto Charge 4000 is a compact, completely automatic, dual channel battery charger
designed for vehicles with a dual battery system. The charger is ruggedized to withstand the
shock and vibration encountered by vehicle mounted equipment.
Charger features:
• Independent charge controls for each battery
• Electronic remote sensing of true battery voltages, eliminates the need
for sensing wires
• Automatic current limiting
• Built-in BATTERY SAVER
• Remote dual battery charge/condition indicator
• Power “ON” LED indicator
• BATTERY SAVER overload indicator
CHARGE CONTROLS & ELECTRONIC REMOTE SENSING
The Auto Charge 4000 contains two independent charge controls, one for each
battery. Automatic electronic remote sensing measures the true voltage of each
battery, eliminating the need for the additional sense wires. The output current of
any charger is inherently a series of pulses whose frequency is determined by the
power line frequency. Therefore there are brief intervals during which no charging
current flows. During this brief interval the Auto Charge 4000 measures and stores
the battery voltage. This voltage is compared to a standard and any error is detected
and used to control the charger output to the desired level. There is no "trickle
charge" and therefore no danger of overcharging and water boil-off.
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AUTOMATIC CURRENT LIMITING
When batteries are severly discharged, some battery chargers can be overloaded
due to the high charging current required. The Auto Charge 4000 contains an
automatic current limit. This current limits the output current to the rated 40 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.
BATTERY SAVER & INDICATOR
A 5 ampere BATTERY SAVER is built into the charger. When connected as shown
in the installation wiring diagram, loads on the battery such as radios and rechargeable hand lights are automatically switched to the BATTERY SAVER when power
is applied to the charger. The BATTERY SAVER allows more efficient charging by
removing these loads. A BATTERY SAVER overload indicator alerts the operator
that the BATTERY SAVER load has exceeded 5 amperes.
WHEN A BATTERY SAVER OVERLOAD OCCURS:
a. Remove the loads for approximately two minutes
b. Reduce the load to 5 amperes or less
c. Reapply the load to the BATTERY SAVER
No fuses are required or provided as the BATTERY SAVER contains an automatic
circuit breaker.
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REMOTE BATTERY CHARGE CONDITION INDICATOR
This remote indicator shows the charge condition of each 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.
NOTE: If a battery is being discharged with an external load of 1.5 to 6
amperes across it’s terminals, the bar graph may move down 1 or 2
levels. This does not indicate a defective battery.
To avoid this, connect all external loads to the BATTERY SAVER
terminals.
Loads connected to the BATTERY SAVER will be powered either from
the BATTERY SAVER power supply when the A.C. power is “ON”, or
they will be connected to battery #1 when the A.C. power is “OFF”.
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/
A
Installation Wiring Diagram
Auto Charge 4000
Strip insulati on
15/32 so tha t
wire strand s are
flus h w ith end of
eyelet, 2 places
COM
REMOTE DISPLAY
43
BAT 2BAT 1
2
POSITIVE
BATTERY SAVER
OVERLOAD
1
POWER
BATTE RY
SAVER
+
1
Indicator
2
V
o
l
t
s
A.C.
POWER
Chassis
Ground
NOTE: Minimum wire size on charger
output and ground is Smaller
gauge wire may cause overheating of
terminal. Use GS 7-13 eyelet over wire
to simplify insertion of wire into terminal
strip and to improve connection
#8 AWG.
CONNECTION DEFINITION WIRE SIZE
A.C. 120 VOLTS A.C. 14 AWG
COM GROUND LINE 8 AWG
BAT 1
BAT 2 POSIT IVE CHAR GING LEAD VEHICLE BATTERY 1 8 AWG
BAT TERY SAVER POSIT IVE OU TPU T 14 AWG
IMPORT AN T: Wire size is for a maximum length of 10 feet. If longer, larger wiringis required.
10/27/2004
Chassis
Ground
Wire Chart
Chassis
Ground
ccessories
Battery Saver Loads
(5 amps max.).
When the charger
is disconnected from
120 volts AC the
Battery Saver loads
automatically are
connected to battery #1.
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SPECIFICATIONS
Input: 120 volt, 50/60 Hz, 8 amperes
Input Fuse: 12 amperes, fast acting
Output: 12 volts D.C. 40 amperes
Remote Sensing: Electronic, sense wires not required
Number of Charger Outputs: 2
Number of Battery Saver Outputs: 1
Battery Saver Output: 12 volts D.C., 5 amperes Max.
Indicators: Power: Red LED, indicates 120 volts power applied
Weight: 24 lbs
Battery Saver Overload: Yellow LED, indicates Battery
Saver load greater than 5 amperes
Bar Graph: indicates charger output and condition of each
battery
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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
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