KUSSMAUL AUTO CHARGE 1000 PUMP Instruction Manual

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BOOK# 091-9-1000 pump plus-reva
4-16-2002
INSTRUCTION MANUAL
AUTO CHARGE 1000
PUMP-PLUS
AIR COMPRESSOR / BATTERY CHARGER
MODEL #091-9-1000
vehicles with single battery system
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
NOTE :
and negative ground.
OUTPUT: 18 AMPERES
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Introduction
The AUTO CHARGE 1000 Pump Plus is a compact, completely automatic, single channel battery charger designed for vehicles with a single battery system. The charger is ruggedized to withstand the shock and vibration encountered by vehicle mounted equipment. The Auto Charge 1000 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:
• Electronic remote sensing of true battery voltages, eliminates the need for sensing wires
• Automatic current limiting
• Built-in BATTERY SAVER
• Remote battery charge/condition indicator
Charge Controls & Electronic Remote Sensing
The Auto Charge 1000 Pump Plus contains a precision voltage controller to maintain the battery’s charge. Automatic electronic remote sensing measures the true battery voltage, 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 their are brief intervals during which no charging current flows. During this brief interval the Auto Charge 1000 Pump Plus measures and stores the battery voltage. This battery voltage is compared to a standard and any error is detected and used to control the charger output at the desired level. Their 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 1000 Pump Plus contains an automatic current limit. This circuit limits the output current to the rated 15 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.
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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 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 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 Battery Charge Condition Indicator
This remote indicator shows 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.
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 the battery when the A.C. power is “OFF”.
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Auto Pump
Air Compressor
Note: make sure the Auto Pump is mounted vertical.
Installation Wiring Diagram
NOTE: INDICATOR WIRING, PIN 1 OF INDICATOR MUST GO TO PIN 1 OF CHARGER, PIN 2 OF INDICATOR TO PIN 2 OF CHARGER AND SO FORTH. PLEASE CHECK CONNECTORS AND COLOR OF WIRES BEFORE PLUGGING IN.
Auto Charge 1000 Pump Plus
PUMP PLUS
11
1
11
22
2
22
33
3
33
44
4
44
1000
AUTOAUTO
AUTO
AUTOAUTO PUMPPUMP
PUMP
PUMPPUMP
++
+
++
COMCOM
COM
COMCOM
CHARGER
POSITIVEPOSITIVE
POSITIVE
POSITIVEPOSITIVE
BAT 1BAT 1
BAT 1
BAT 1BAT 1
BATTERY SAVER OVER LOAD
AUTOAUTO
AUTO
DCDC
DC
DCDC
AUTOAUTO PUMPPUMP
PUMP
PUMPPUMP
B.S.B.S.
B.S.
B.S.B.S.
POWERPOWER
POWER
POWERPOWER
ACAC
AC
ACAC
Pressure Switch
BLK
BLK
RED
RED
Chassis
Range
Nut
Ground
WIRE SIZE CHART
CONNECTION ITEM DEFINITION WIRE SIZE
COM
BATTERY COMMON
BAT 1
B.S.
BATTERY#1POSITIVE CHARGING LEAD
BATTERY
SAVER
AUTO
PUMP+
AUTO
PUMP-
AUTO PUMP
AUT O
PUMP
NEGATIVE CHARGING LEAD FOR CHARGING BATTERIES AND BATTERY SAVER LOAD
FOR BATTERY # 1 POSITIVE LEAD FOR BATTERY
SAVER LOADS. AUTO PU MP, POSITIVE 14 AW G
AUTO PUMP, NEGATIVE 14 AW G
Chassis Ground
Chassis Ground
12 AW G
12 AW G
16 AW G
+ 12 Volts
Battery Saver Loads
(3 amps max.). When the charger is disconnect from 120 volts AC the Battery Saver loads automatically are
Accessories
connected to battery #1.
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 ampere, fast acting Output: 12 volts D.C. 15 amperes Max. Remote Sensing: Electronic, sense wires not required Number of Charger Outputs: 1 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
Bar Graph: indicates charger output and state of charge of
battery
Weight: 16 lbs
Outline Dimensions, AUTO CHARGE 1000
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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 liability for any damages which may result from its installation, use or misuse, by the purchaser, his or its employees or others.
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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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