Kussmaul 091-92-12 User Manual

FILE: IM_091-92-12_Rev_B

DATE: 09-15-04

INSTRUCTION MANUAL

BATTERY SAVER

LOW RIPPLE POWER SUPPLY / AUTOMATIC LOAD SWITCH

FOR 12VDC VEHICLE SYSTEMS

MODEL #091-92-12

INPUT: 115 VOLTS, 50/60 Hz AC, 1.8 amps. RMS

OUTPUT: 13.2VDC, 10 AMPS DC, 130VA

3 YEAR WARRANTY

KUSSMAUL ELECTRONICS CO., INC.

170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221

TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]

INTRODUCTION

The 091-92-12 BATTERY SAVER is a power supply with a load power transfer function.
Loads connected to the BATTERY SAVER are powered by the vehicle’s battery when the
AC power to the 091-92-12 Battery Saver is OFF. When AC power is applied to the 091­92-12 Battery Saver special circuitry within the Battery Saver transfers the load(s) to a
power supply internal to the 091-92-12 Battery Saver. The Battery Saver power supply then
provides low ripple 12VDC System power to Battery Saver load(s). Installation of a 091­92-12 Battery Saver eliminates the power drain on a vehicle battery and or a battery under­charge ensuring all vehicle battery charger power is available to charge the battery.
The 091-92-12 Battery Saver is unique in that there is no interruption of power supplied to
the loads during power transfers. The feature makes the 091-92-12 Battery Saver ideal for
MDT (Mobile Data Terminal) and or 12VDC vehicle computer systems that may "re-boot"
during an input power interruption.

INSTALLATION

1. Mount the BATTERY SAVER in a convenient location with 4 screws in the
mounting holes provided. Be certain that adequate ventilation is available and that
the unit is not subject to weather damage.

2. Connect the 115VAC input power to the BATTERY SAVER through a 3-wire line
cord as shown in INSTALLATION WIRING DIAGRAM, Figure 1.

3. The low voltage connections are made through the DC output connector as shown
in INSTALLATION WIRING DIAGRAM, FIGURE 1.

1. Connect terminal 1 to the vehicle’s 12 volt battery (+).

2. Connect terminal 3 to the +12 volt electrical loads.

3. Connect terminal 4 to the vehicle ground or to the battery (-).

The installation is now complete. Loads connected to the Battery Saver will be powered
from the vehicle battery when the AC power to the Battery Saver is OFF and from the Battery
Saver power supply when the AC power is ON.

TEST and OPERATION

The 091-92-12 Battery Saver system interface panel contains two (2) Green LEDs as
follows: Refer INSTALLATION WIRING DIAGRAM, Figure 1.
"LOAD POWER" LED: Illuminates when power is being supplied to the load(s) regardless

of the source of the power (Vehicle Battery or Battery Saver).

"BATT SVR PWR" LED: Illuminates when Battery Saver is receiving AC power and the

power supply internal to the Battery Saver is ON and functioning.

Installation Test

1. Remove AC power from the 091-92-12 Battery Saver.

2. Verify "LOAD POWER" LED is illuminated and loads are being powered by vehicle
battery (voltage at load is approximately equal to vehicle battery terminal voltage).

3. Apply AC power to 091-92-12 Battery Saver and verify:

1."LOAD POWER" LED remains illuminated

2. "BATT SVR PWR" LED illuminates approximately five (5) seconds after
application of AC power to Battery Saver.

3. Load voltage is between 13.2VDC and 13.4VDC

Operation

The 091-92-12 Battery Saver contains special circuitry that eliminates power delivery
"glitches" or interruptions during load power transfer(s) from:

*Vehicle Battery to Battery Saver: Five (5) second delay as Battery Saver power

supply stabilizes. Installation Test para. 3.2.

*Battery Saver to Vehicle Battery: No delay

The MINIMUM voltage at the load during any power transition is:

Vehicle Battery VDC - 1.3VDC for a MAXIMUM of 150 milli-seconds (.150 seconds).

INSTALLATION PRECAUTIONS

Refer Figure1, INSTALLATION WIRING DIAGRAM and Specifications & Outline

The 091-92-12 Battery Saver is AC Input AND DC Output over-current protected as follows:
115VAC 60Hz Input: 5 Ampere
DC Output: ATC, 10 Ampere
The ATC 10 Ampere DC OUTPUT FUSE internal to the Battery Saver is common to both
the Battery Saver Power Supply output AND the vehicle battery connection that supplies
power to the load when the Battery Saver is OFF (115VAC to Battery Saver - OFF). Current
OVERLOADING the Battery Saver in excess of 10 Amperes will:

Initiate current limiting of the Battery Saver Power Supply with a corresponding
reduction of the Battery Saver Power Supply terminal voltage when the Battery
Saver is ON until the DC OUTPUT FUSE open circuits.

OR

Cause the ATC 10 Ampere DC OUTPUT FUSE to open circuit while a Battery Saver
connected load in excess of 10 Amperes is being supplied by the vehicle battery with
the Battery Saver OFF.

Manage Battery Saver Connected Loads to 10 Amperes or less!

INSTALLATION WIRING DIAGRAM

FIGURE 1

AC INPUT FUSE

* LOCATED UNDER COVER * LOCATED UNDER COVER

SYSTEM INT ERFAC E
PANEL

115VAC, 60Hz

115VAC INPUT

123

LINE, AWG 18
NEUTRAL , A W G 18
EART H , AWG 1 8

* REFER TO INSTALLATION PRECAUTIONS

and SPEC IFICATION S

SYSTEM GROUND

BATT SVR DC OUT

12VDC BAT + IN

LOAD POWER

NL

BATT SVR PWR

BATT SVR PWR

"ON" GREEN LED

LOAD PWR "ON"
GREEN L ED

DC OUTPUT FUSE

DC SYSTEM

AIR INLET

KEEP CLEAR

DC OUTPUT
CONNECTOR

SYSTEM CABLING CONNECTORS

SUPPLIED WITH 091-92-12 BATT SVR.

12V VEH ICLE

BATTERY

12

43

12V VEHICLE

GROUND

+

ACCESSORIES RADIOS HAND LIGHTS

SPECIFICATION & OUTLINE

SPECIFICATIONS:
Input Power: 115 volts AC., 50/60Hz, 1.8 Amperes RMS
Input Fuse: F1, 5 Ampere, fast acting, 5 X 20mm, Littlefuse

P/N 21605, inside enclosure

Output Voltage: 13.2 Volts, D.C. ( factory adjustable)
Output Ripple: 30 millivolts, AC., RMS
Output Current: 10 Amperes, D.C.
Electronic Current Limit: 10 Amperes D.C. from Battery Saver Power Supply

Please refer to Installation Precautions

Output Fuse: F2, 10 Ampere, fast acting Autofuse,

Littlefuse P/N 257010, inside enclosure

Please refer to Installation Precautions

Indicator(s): 1. LOAD POWER ON Green LED

2. BATTERY SAVER POWER SUPPLY ON Green LED

Size: 11.15" L x 5.75" W (air inlet grills) x 2.5" H
Mounting Hole Diameter: .191"
Weight: 2.5 lbs

11.15

5.75

3.50

11.75

9/32" DIA. 4 HOLES

2.50

OUTLINE DRAWING

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 employees or
others.