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FILE: 091-9-2000.P65
DATE: 4-23-2000
REV. A
INSTRUCTION MANUAL
AUTO CHARGE
2000
PUMP-PLUS
AIR COMPRESSOR / BATTERY CHARGER
INPUT :120 volt, 50/60 Hz, 3.5 amps
1 YEAR WARRANTY ON AIR COMPRESSOR
3 YEAR WARRANTY ON CHARGER
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
MODEL #091-9-2000
NOTE :
This charger is designed for
vehicles with dual batteries
and negative ground.
OUTPUT: 18 AMPERES
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INTRODUCTION
The AUTO CHARGE 2000 is a compact, completely automatic, dual channel
battery charger designed for vehicles with two batteries. The charger is ruggedized to withstand the shock and vibration encountered by vehicle mounted
equipment. The Auto Charge 2000 Pump Plus operates an 091-9 air compressor. With the
selector switch in the AC position the compressor runs only when the AC power is applied.
With the selector switch in the DC position the compressor will operate when the AC power
is on or off. In either position the compressor operates from the vehicle’s batteries, the Pump
Plus automatically recharging the batteries as required.
The battery charger features:
• Independent charge controls for each battery
• Electronic remote sensing of true battery voltages, eliminates the need
for sensing wires
• Automatic current limiting and apportionment
• Built-in BATTERY SAVER
• Remote dual battery charge/condition indicator
• Power “ON” LED indicator
• BATTERY SAVER overload indicator
DESCRIPTION
Independent Charge Controls & Electronic Remote Sensing
The charger contains two independent charge controls, one for each battery.
This allows each battery to be independently charged while maintaining battery
isolation. Each battery voltage is remotely sensed, electronically, eliminating the
need for four sense wires. Each of the charge controls is completely automatic and
stops charging the battery when it is fully charged. There is no trickle charge and
therefore no danger of overcharging and water boil-off.
Automatic Current Limiting & Apportionment
The charger contains automatic current limiting at 15 amperes. This is a total
current limit for the two batteries combined. The charger automatically apportions
the current to each battery. Either battery can draw the total 15 amperes. When
charging unequally charged batteries, the lower charged battery receives a higher
charge rate. When the batteries are equal, the current is shared equally until they
are fully charged at which time the current goes to zero.
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Battery Saver & Indicator
A 3 ampere BATTERY SAVER is built into the charger. When connected as
shown in the installation wiring diagram, loads on battery #1 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 3 amperes.
WHEN A BATTERY SAVER OVERLOAD OCCURS:
a. Remove the loads for approximately two minutes
b. Reduce the load to 3 amperes or less
c. Reapply the load to the BATTERY SAVER
No fuses are required or provided as the BATTERY SAVER contains an electronic
overload interrupter.
Remote Dual 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 charged with an external load of 1.5 to 4 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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Installation Wiring Diagram
WIRE SIZE CHART
CONNECTION ITEM DEFINITION WIRE SIZE
COM
BAT 1
BAT 2
B.S.
AUTO
PUMP+
AUTO
PUMP-
BATTERY
COMMON
BATTERY#1POSITIVE CHARGING LEAD
BATTERY#2POSITIVE CHARGING LEAD
BATTERY
SAVER
AUTO
PUMP
AUTO
PUMP
NEGATIVE CHARGING LEAD
FOR CHARGING BATTERI ES
AND BATTERY SAVER LOAD
FOR BATTER Y # 1
FOR BATTER Y # 2
POSITIVE LEAD FO R BATTERY
SAVER LOADS.
AUTO PUMP, POSITIVE 14 AWG
AUTO PUMP, NEGAT IVE 14 AWG
12 AWG
12 AWG
12 AWG
16 AWG
IMPORTANT : Wire size is
for a maximum length of 10
feet. If wiring is to be longer,
larger wiring is required. Additional information is available on request.
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Specifications:
Input: 120 volt, 50/60 Hz, 3.5 amperes
Input Fuse: 6 amperes, fast acting
Output: 12 volts D.C. 15 amperes Max., total both outputs
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., 3 amperes Max.
Indicators: Power: Red LED, indicates 120 volts power applied
Battery Saver Overload: Yellow LED, indicates Battery Saver
load greater than 3 amperes
Dual Bar Graph: indicates charger output to two batteries and
state of charge of batteries
Weight: 16 lbs
Outline Dimensions, AUTO CHARGE 2000
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INDICATOR INSTALLATION
1. Locate Indicator in a convenient place on the vehicle.
2. Place the template in position and center punch in 4 places.
3. Drill holes as shown.
5. Cut out square hole.
6. Connect wiring to charger using butt connector supplied.
7. Install as shown.
8. Insert 4 #6-32 screws and tighten, (CAUTION Do not over tighten because
you will bend the plastic bezel and brake the watertight seal).
HOLE TEMPLATE
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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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