KUSSMAUL PUMP PLUS 1200 091-193-12 Instruction Manual

Page 1
PUMP PLUS 1200
AUTOMATIC SINGLE OUTPUT BATTERY CHARGER
Unit supplied with
one of these displays
MODEL #: 091-193-12
INPUT: 120 Volt, 60 Hz, 10 Amps
File: IM_091-193-12_revG.indd Rev: G Revised By: JM Date: 03-20-2015
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
OUTPUT: 40 Amps
3 YEAR WARRANTY
scan using your mobile
device for more information
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 suf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
2
Page 3
INTRODUCTION
The Pump Plus 1200 is a compact, completely automatic, 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.
FEATURES
I. PUMP PLUS 1200 BATTERY CHARGER
Electronic remote sensing of true battery voltage, eliminates the need for sensing wires
Automatic current limiting
Remote Battery charge/condition indicator display
LED status indicators
Pump output with AC or DC mode rocker switch
• NEW! Battery Selector Switch allows for Lead-Acid or AGM modes
II. CHARGE CONTROLS & ELECTRONIC REMOTE SENSING
The Pump Plus 1200 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, there are brief intervals during which no charging
current ows. Since there is no charging current there is also no voltage drop between the charger
and the battery. The Pump Plus 1200 measures and stores the true battery voltage. This battery 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-off.
III. AUTOMATIC CURRENT LIMITING
When batteries are severely discharged, some battery chargers can be overloaded due to the high charging current required. The Pump Plus 1200 contains an automatic current limit. The current limit feature limits the output current to 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.
IV. PUMP OUTPUT
The output terminal strip provides an additional output to accomodate the Auto Pump 12V, Part Number 091-9-12V. The Auto Pump output works in conjunction with a front panel mounted rocker switch. For normal operation, the rocker switch should be left in AC mode, which means that the Auto
Pump works only when shoreline power is supplied to the charger. With the switch in DC mode the
compressor will operate when AC power is ON or OFF. In either position the compressor operates from the vehicle’s batteries, while the charger automatically recharges the batteries as required.
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
3
Page 4
V. LED STATUS INDICATORS
Length of Wire to Battery (feet)
V. BAT + A. PUMP +
COM -
V. BAT + A. PUMP +
COM -
V. BAT + A. PUMP +
COM -
091-TERFER812
091-TERFEB148
091-TERFER812
091-TERFEB612
091-TERFEB148
091-TERFEB612
091-TERFEY1012
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
1. BATTERY CONNECTED: Indicates that a battery of proper polarity is connected to the charger output terminals
2. FAN ON: Indicates that the fan is operating. Fan operates whenever output exceeds 10 amperes. Fan turns off when output current decreases below 5 amperes
3. POWER: Indicates that AC voltage is present
VI. BATTERY SELECTOR SWITCH
Allows selection between Lead-Acid and AGM style batteries. The default factory setting of the switch is set to in the Lead-Acid position.
WIRING
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. Make sure the position of the Battery Selector Switch matches your battery type. The switch pro-
vides for operation in Lead-Acid or AGM style batteries. Refer to Installation Wiring Diagram III.
4. Double check all wiring before applying AC power to input terminal.
5. Apply AC power (shoreline power) to input terminal and observe that the charger is operating.
6. Verify that the battery voltage appears at the charger output terminals. A minimum of 6 volts is required to start the charger
II. WIRING SPECIFICATIONS
Battery Charger Connections
Wire # Gauge (awg) 8 14 8 6 14 6 4 12 4
Wire Ferrule Used
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
none
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
none
4
Page 5
INSTALLATION WIRING DIAGRAM
I. FOR BAR GRAPH DISPLAY, 091-199-001 OR DELUXE STATUS CENTER, 091-194-IND
Wiring Diagram shown is for a 10 foot installation
5
Page 6
II. FOR WATERTIGHT DELUXE STATUS CENTER, 091-194-IND-WT-XX
Wiring Diagram shown is for a 10 foot installation
6
Page 7
BATTERY SELECTOR SWITCH
Use a mini precision slotted screwdriver to select AGM or Lead-Acid
7
Page 8
SPECIFICATIONS
Input Power: 120 Volt, 60 Hz, 10 Amperes
Input Fuse: 15 Ampere, resettable, circuit breaker
Pump Fuse: 15 Ampere, resettable, circuit breaker
Output Power: 12 Volts DC, 40 Amperes Max
Battery Selector Switch: Lead-Acid: 13.25 / AGM: 13.50
Remote Sensing: Electronic, sense wires not required
Torque: DC output connector: 20 in. lbs
LED Status Indicators: Battery Connected, Fan On, and Power On
Hardware Pack Provided: (2) #6 AWG Blue Ferrules, P/N: 091-TERFEB612
(1) #14 AWG Blue Ferrule, P/N: 091-TERFEB148
Charger Indicators: Remote Bar Graph Display, Deluxe Status Center or Waterproof Status Center
Output Waterproof Circuit Breaker (Optional): 80 Amperes, P/N: 090-0080-0
Output Buss Bar (Optional): 5 Studs, P/N: 002-3595-5
Weight: 27 pounds
OUTLINE DRAWING
170 Cherry Avenue West Sayville, NY 11796 www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
8
Page 9
OPTIONAL ACCESSORIES
I. BAR GRAPH DISPLAY, MODEL #: 091-199-001
10-Segment LED display indicate the “state of charge” and the general condition of the batteries
II. DELUXE STATUS CENTER, MODEL #: 091-194-IND
• Indicator has a digital voltage and ampere display
• 5 segment bar graph display indicates output current
4 LED’s to show the condition of the batteries
III. WATERTIGHT DELUXE STATUS CENTER, MODEL #: 091-194-IND-WT-XX
• Indicator has digital voltage and ampere display
• 5 segment bar graph display indicates output current
4 LED’s to show the condition of the batteries
• Indicator is housed in a watertight bezel
• Bezel is available in 6 different colors, Red, White, Blue, Yellow, Gray, and Black Specify color choice when ordering
IV. WATERPROOF CIRCUIT BREAKER, MODEL #: 090-0080-0
• 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
V. 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
9
Page 10
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
10
Loading...