KUSSMAUL AUTO CHARGE 4000 Instruction Manual

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INSTRUCTION MANUAL
®
AUTO CHARGE 4000
LOW PROFILE CHARGER
AUTOMATIC DUAL OUTPUT BATTERY CHARGER
Unit supplied with
this display
MODEL #: 091-89-12
INPUT: 120 Volt, 50/60 Hz, 5 Amps
File: IM_091-89-12_GEN2_revA Revised By: PSS/JRN Date: 05-11-2018
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
Page 2
IMPORTANT SAFETY INSTRUCTIONS
I. PERSONAL PRECAUTIONS:
1. Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye and clothing protection. Avoid touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If battery acid enters
the eye, immediately ood eye with cold running water for at least 10 minutes and get medical attention
immediately.
5. NEVER smoke or allow a spark or ame in the vicinity of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit
the battery or other electrical part and cause a re or an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
lead-acid battery. A lead-acid battery, when shorted, can produce a current su󰀩cient to weld a ring or the
like metal causing a severe burn.
8. Use the battery charger for charging gel-cell, AGM and ooded lead-acid batteries only. Do not use the charger for charging dry-cell batteries that are commonly used with home applications. These batteries may burst and cause injury to persons and damage to property.
9. WARNING – RISK OF EXPLOSIVE GASES: Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation.
II. CHARGER PRECAUTIONS:
1. NEVER charge a frozen battery.
2. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
3. Do not operate the charger with a damaged cord or plug; replace them immediately.
4. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged.
5. Do not disassemble the charger. Incorrect reassembly may result in a risk of electric shock and re.
6. To reduce the risk of electric shock, disconnect the charger from the AC source before attempting any maintenance or cleaning.
7. LOCATION OF CHARGER: The charger should be mounted on a wall, vehicle oor, ventilated compart­ment or other suitable surface as close to the batteries to be charged as possible. Do not block the char­ger’s fan or air intakes. Do not mount the charger directly over the batteries as fumes may cause exces-
sive corrosion. The area should be well ventilated and free from excessive moisture, exhaust manifolds, and battery fumes. For maximum performance, the charger should not be located in an area of extreme
high temperature. The charger is not waterproof. Do not mount the charger where there is a possibility of
water entering the unit. Evidence of water entry into the charger will void the warranty.
8. CAUTION: Do not attempt to increase battery bank capacity by splitting the output of one of the banks
with a diode-type battery isolator. The diode isolator lowers the charger voltage and results in under­charging the batteries connected to it. If additional capacity is required it is preferable to add another isolated or parallel battery.
III. GROUND AND AC POWER CORD CONNECTION:
1. The charger should be grounded via the AC power connection to reduce the risk of electrical shock.
2. The charger must be plugged into or wired to an outlet that is an over-current protected 3 prong outlet. Alternatively, it may be routed through a separate dedicated fuse or circuit breaker on an AC distribution panel with proper earth/safety ground. All wiring shall comply with UL recommendations, NEC or NFPA
standards and local ordinances. Never alter the AC cord or plug if provided. Any modication of the cord must only be done by a qualied electrician. Improper cord/outlet connection may result in a risk of elec-
trical shock.
3. Observe color coding of the AC wiring as follows:
Black………....................... AC Hot or LINE (fused)
White…………................... AC Neutral
Green…….................…….. AC Ground (safety/earth)
4. CAUTION: (230 VAC applications only): If AC input is provide from a source consisting of two HOT or
LINE leads (phase-to-phase 230 VAC input voltage); an external fuse or circuit breaker must be used to
protect both hot leads.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
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INTRODUCTION
The New and Improved Auto Charge 4000, LPC, is a low prole, microprocessor controlled, completely
automatic, dual channel battery charger designed for vehicles with a dual battery system. This latest generation of LPC charger improves upon user selectable functions, which includes user selectable battery type. The LPC charger is also designed to withstand the shock and vibration encountered by vehicle mounted equipment.
FEATURES
I. Auto Charge 4000
• Automatic current limiting
• Voltage regulated output
• Remote dual battery charge/condition indicator display
• Accommodates Lead-Acid, Gelled Electrolyte, AGM and Odyssey® battery types
• Power “ON” LED indicator
• System Status indicator
• Internal cooling fan
II. CHARGE CONTROLS & ELECTRONIC REMOTE SENSING
The AC 4000, LPC, contains a precision voltage controller to maintain the battery’s charge. The output terminal is voltage regulated, and internal circuitry provides for constant power during loaded situations. 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-o󰀨.
III. AUTOMATIC CURRENT LIMITING
When batteries are severely discharged, some battery chargers can be overloaded due to the high charging current required. The AC 4000,LPC, contains an automatic current limit. The current limit feature limits the output current 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
IV. BATTERY SELECTOR SWITCH (LEAD-ACID, GEL-CELL, AGM, or ODYSSEY®
DIP switches are used to select between various battery chemistries.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
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V. AUX OUTPUT
The output terminal strip provides an additional output to accommodate 12 volt accessories, such
as Kussmaul’s 12 VDC air pump. The AUX output works in conjunction with a front panel mounted DIP switch. For normal operation, the DIP 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. If AC power is o󰀨, the aux ouput
operates from the vehicle’s batteries.
VI. LED STATUS INDICATORS
a. POWER: Green LED, indicates AC power is present. b. SYSTEM: See specications page for description of system status.
VII. COOLING FAN
The AC 4000,LPC is fan cooled and automatically cycles on and o󰀨 depending on output current. When the fan is on, air is circulated and exhausted through the right side. The fan cycles briey when
power is applied in order to verify that it is functioning.
OPERATION
I. BATTERY TYPE SELECTION SWITCHES
Switches “1” and “2” should be used to match the battery chemistry. Units are shipped with all switched down (default setting). Switches can be set at follows:
Lead-Acid - Both switches down (o󰀨) - factory default setting Gelled Electrolyte (Gel-Cell) - Switch “1” down (o󰀨) and Switch “2” up (on) AGM - Switch “1” up (on) and Switch “2” down (o󰀨)
Odyssey® - Both switches up (on)
NOTE: See specications for battery selector switch absorption and oat voltage settings.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
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II. AUX OUTPUT
Switch “5” controls the Aux output operating mode.
AC – Switch “5” down (o󰀨) - factory default setting. DC – Switch “5” up (on).
In AC mode, the Aux accessories will operate only when AC power is applied to the battery charger.
In DC mode, the Aux accessories will operate when the AC power is on or o󰀨. The Aux accessory
is powered by the charger while AC power is applied to the charger and from the vehicle’s battery when no AC power is applied.
III. REMOTE BATTERY CHARGE CONDITION INDICATOR (Standard equipment)
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 the 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 its terminals, the bar graph may move down 1 or 2 levels. This does not indicate a defective battery. To avoid this, either reduce constant load draws or consider an external Battery Saver. Please contact Kussmaul Electronics for further details.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
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WIRING
091-89-12
091-TERFER812
091-TERFER812
091-TERFER812
091-TERFEB148
091-TERFEB612
091-TERFEB612
091-TERFEB612
091-TERFEB148
091-TERFEB148
0-5
5 - 10**
10 - 20*
* Consult factory if length of wire to battery is longer than 20 feet
** Supplied with wire terminal hardware for 10 foot installation
I. BATTERY CHARGER WIRING INSTRUCTIONS
1. Refer to Installation Wiring Diagram I and II.
2. Refer to Wiring Specications to determine the recommended wire size and maximum lengths. Using a smaller gauge may cause overheating of the terminal. Additional informa­tion is available upon request if longer, larger wiring is required.
3. Double check all wiring before applying AC power to input terminal.
4. Apply AC power (shoreline power) to input terminal and observe that the charger is oper­ating.
5. Verify that the battery voltage appears at the charger output terminals. A minimum of 9 volts is required to start the charger.
II. WIRING SPECIFICATIONS
Length of Wire to Battery (feet)
Battery Charger Connections
COM -
Wire # Gauge (awg) 8 8 8 14 6 6 6 14 4 4 4 14
Wire Ferrule Used
BAT 1+
BAT 2+
B.S. +
COM -
BAT 1+
BAT 2+
B.S. +
COM -
none
BAT 1+
BAT 2+
none
none
B.S. +
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
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INSTALLATION WIRING DIAGRAM
I. FOR BAR GRAPH DISPLAY, 091-39-IND
1 - RED 20AWG 2 - BLACK 20AWG 3 - WHITE 20AWG 4 - GREEN 20AWG
AUTO CHARGE
4000
SEE TOP OF CHARGER
FOR INFORMATION
50 Amp Waterproof Circuit Breaker
Kussmaul Part #: 090-0050-0
Or Fuse, Place near the battery
AC Connections shall
3’ IEC Power Cord, 16/3AWG, Supplied with unit
RED (8AWG)
RED (8AWG)
POWER
SYSTEM
INDICATOR
1 2 3 4 5
Buss Bar
Or Chassis Ground
RED (12AWG)
To 12 Volt
Accessories
002-3595-5Kussmaul Part #:
+
-
Y
R
E
OUTPUT
AUX
BAT1
+
+
RED (8AWG)
RED (8AWG)
BLACK (8AWG)
BLACK (8AWG)
-
+
BLACK (8AWG)
Y
R
E
T
T
A
B
R
BAT2
+
T
T
A
B
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
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DIP SWITCH SETTINGS
ON
OFF
SWITCH SHOWN
IN OFF POSITION
Legend on front panel of charger
=
ON
This is what the dip switch should look like when setting it to the legend on the front panel of the charger.
1 2 3 4 5 6 7 8
O N
1
BATTERY
TYPE
LEAD
GEL AGM ODY
AC DC
AUX
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SPECIFICATIONS
Input Power: 100-130 Volts, 50/60 Hz, 6 Amperes Max Input Fuse: (2) - 8 amp, fast acting, 5X20mm Output Power: 12 Volts DC, 45 Amperes Max Operating Temperature Range: -25ºC to 50ºC
Aux Output: 12 Volts, 15 Amperes Max, internally fused
Battery Selector Switch:
Battery Type Float VDC +/- 1%
Lead-Acid 13.25 Gelled Electrolyte 13.50 AGM 13.50 Odyssey ® 13.60
Output Connector Type: Spring clamp; Tooless Termination LED Status Indicators:
Power: Green LED, Indicates 120 Volt AC power applied System: Yellow LED: Fast Flash (5 times per Second) indicates battery reverse polarity Slow Flash (once per second) indicates no battery is connected Solid On indicates charger is in current limit (normal operation) Solid O󰀨 indicates (normal operation)
Hardware Pack Provided: (1) 3-ft IEC cord Charger Indicators Options: Remote Bar Graph Display, 091-39-IND Output Waterproof Circuit Breaker (Recommended): 60 Amperes, PN 090-0060-0 Output Buss Bar (Optional): 5 Studs, P/N: 002-3595-5
Weight: 7 pounds
OUTLINE DRAWING
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OPTIONAL ACCESSORIES
I. BAR GRAPH DISPLAY, MODEL #: 091-39-IND
10-Segment LED display indicate the “state of charge” and the general condition of the batteries
II. 50 AMP WATERPROOF CIRCUIT BREAKER, MODEL #: 090-0060-0
• Combines switching and circuit breaker function
Compact size and surface mount conguration
• Protects high amperage circuits
• Latch arms resets breaker after overload
• Cannot be held in ON position if short remains on circuit
• Waterproof - Ideal for truck applications
III. E-Z SLIDE MOUNTING PLATE, MODEL #: 091-200-EZM
• Locking mounting system
• Ease the installation and the removal of larger sized chargers that are in harder to access areas, such as under seats
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
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INSTALLATION RECORD
DATE INSTALLED _______________________________________________________
INSTALLED BY _________________________________________________________
VEHICLE IDENTIFICATION _______________________________________________
VEHICLE OWNER _______________________________________________________
WARRANTY POLICY
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.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
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